Download pdf - Mountain bicycle manual S1000D Sample Publication - Libroplanta - Libroplanta S1000D …4.1].pdf · 2017-04-16 · S1000DBIKE-C3002-LOAP1-00 UNCLASSIFIED S1000DBIKE-AAA-D00-00-00-00AA-002A-A

UNCLASSIFIED S1000DBIKE-C3002-LOAP1-00Pr

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S1000DBIKE-AAA-D00-00-00-00AA-001A-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)

UNCLASSIFIED 2012-12-31 Page 1

S1000D Sample Publication

Mountain bicycleMountain storm Mk1Brook trekker Mk9

Mountain bicycle manual

BIKE

S1000DBIKE-C3002-EPWG1-00

Issue No. 001, 2010-06-08

To be made available to all S1000D users.Export control:

Export registration statement: ....................................................... Export of this publication to all countries that are the residence oforganizations that are users of S1000D is permitted.

Users may destroy this publication in accordance with any local procedures.There are no dissemination limitations that apply to this publication.

End of data module

Publisher:LIBROPLANTA


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List of effective data modules

Document title Data module code Issue dateIssue No.

No. ofpages

Applicable to

Bicycle — Description of how itis made

S1000DBIKE-AAA-D00-00-00-00AA-041A-A

2008-08-01 3

Bicycle — Description offunction

S1000DBIKE-AAA-D00-00-00-00AA-042A-A

2008-08-01 3

Bicycle — Description attributedto crew

S1000DBIKE-AAA-D00-00-00-00AA-043A-A

2008-08-01 2

Mountain bicycle — Applicabilitycross-reference table catalog

S1000DBIKE-AAA-D00-00-00-00AA-0A3A-D

2010-02-18 1

Bicycle — Pre-operationprocedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

2008-08-01 6

Bicycle — Riding a bicycle S1000DBIKE-AAA-D00-00-00-00AA-130A-A

2007-01-01 3

Bicycle — Normal operationprocedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-131A-A

2008-08-01 3

Bicycle — Post-operationprocedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-151A-A

2008-08-01 3

Bicycle — Servicing: Attention S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T10B

2009-10-19 2

Bicycle — Servicing:Prerequisite concept review

S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T36D

2009-10-19 2

Bicycle — Other procedures toclean

S1000DBIKE-AAA-D00-00-00-00AA-258A-A

2008-08-01 7

Bicycle — Place on test stand S1000DBIKE-AAA-D00-00-00-00AA-330A-A

2008-08-01 3

Bicycle — Standard repairprocedures

S1000DBIKE-AAA-D00-00-00-00AA-663A-A

2008-08-01 13

Bicycle — Performance support S1000DBIKE-AAA-D00-00-00-00AA-952A-T-H31A

2009-07-22 9


2009-07-22 9

Bicycle — Illustrated Parts Data- IPD

S1000DBIKE-AAA-D00-00-00-01AA-941A-D

2008-08-01 2

Bicycle — Time limits S1000DBIKE-AAA-D05-10-00-00AA-000A-A

2008-08-01 1

Bicycle — Scheduledmaintenance lists

S1000DBIKE-AAA-D05-20-00-00AA-000A-A

2008-08-01 12

S1000DBIKE-C3002-LOAP1-00 UNCLASSIFIED

S1000DBIKE-AAA-D00-00-00-00AA-002A-A

Page 2 2012-12-31 UNCLASSIFIED

Applicable to:Mountain bicycle and (Mountain

storm Mk1 or Brook trekker Mk9)


No. ofpages

Applicable to

Bicycle — Scheduledmaintenance checks

S1000DBIKE-AAA-D05-40-00-00AA-000A-A

2008-08-01 2

Wheel — Description of how it ismade

S1000DBIKE-AAA-DA0-00-00-00AA-041A-A

2008-08-01 6

Wheels — Description of how itis made: Knowledge Check

S1000DBIKE-AAA-DA0-00-00-00AA-041A-T-T61E

2009-10-02 1

Inner tube — Remove andinstall a new item


2008-08-01 4

Tire — Fill with air S1000DBIKE-AAA-DA0-10-20-00AA-215A-A

2008-08-01 3

Tire — Check pressure S1000DBIKE-AAA-DA0-10-20-00AA-362B-A

2008-08-01 3

Front wheel — Fault reports andisolation procedures


2008-08-01 3

Front wheel — Removeprocedures: Interactive content -Procedure

S1000DBIKE-AAA-DA0-10-20-00AA-520A-T-T4JC

2009-10-02 3

Tire — Remove and install anew item


2008-08-01 3

Rear wheel — Detected fault S1000DBIKE-AAA-DA0-20-00-00AA-412A-A

2008-08-01 2

Rear wheel — Removeprocedures


2008-08-01 3

Brake system — Description ofhow it is made


2008-08-01 8

Brake system — Manual test S1000DBIKE-AAA-DA1-00-00-00AA-341A-A

2008-08-01 3

Brake pads — Clean withrubbing alcohol


2008-08-01 3

Steering — Description of how itis made


2008-08-01 2

Steering — Description of how itis made: Knowledge Check


2009-07-30 2

Stem — Remove procedures S1000DBIKE-AAA-DA2-10-00-00AA-520A-A

2008-08-01 4

Stem — Install procedures S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

2008-08-01 7

Handlebar — Removeprocedures


2008-08-01 7

(Continued)


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No. ofpages

Applicable to

Handlebar — Install procedures S1000DBIKE-AAA-DA2-20-00-00AA-720A-A

2008-08-01 4

Headset — Description of how itis made


2008-08-01 3

Headset — Remove procedures S1000DBIKE-AAA-DA2-30-00-00AA-520A-A

2008-08-01 5

Headset — Install procedures S1000DBIKE-AAA-DA2-30-00-00AA-720A-A

2008-08-01 3

Frame — Description of how itis made


2008-08-01 3

Horn — Isolated fault S1000DBIKE-AAA-DA3-10-00-00AA-411A-A

2008-08-01 2

Horn — Remove and install anew item


2008-08-01 3

Drivetrain — Description of howit is made


2008-08-01 1

Chain — Oil S1000DBIKE-AAA-DA4-10-00-00AA-241A-A

2008-08-01 9

Chain — Clean with chaincleaning fluid

S1000DBIKE-AAA-DA4-10-00-00AA-251B-A

2008-08-01 3

Drive train — Correlated fault S1000DBIKE-AAA-DA4-10-00-00AA-414A-A

2008-08-01 2

Gears — Description of how it ismade


2008-08-01 1

Mechs — Description of how itis made


2008-08-01 5

Hubs — Clean with degreasingagent

S1000DBIKE-AAA-DA5-20-00-00AA-251C-A

2008-08-01 5

Shifters — Description of how itis made


2008-08-01 7

(Continued)

End of data module


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Table of contents


No. ofpages

Applicable to

Bicycle — Description of how it ismade

S1000DBIKE-AAA-D00-00-00-00AA-041A-A

2008-08-01 3 Mountain bicycleand (Mountainstorm Mk1 orBrook trekkerMk9)

Bicycle — Description of function S1000DBIKE-AAA-D00-00-00-00AA-042A-A


Bicycle — Description attributed tocrew

S1000DBIKE-AAA-D00-00-00-00AA-043A-A


Mountain bicycle — Applicabilitycross-reference table catalog

S1000DBIKE-AAA-D00-00-00-00AA-0A3A-D


Bicycle — Pre-operation procedures(crew)

S1000DBIKE-AAA-D00-00-00-00AA-121A-A


Bicycle — Riding a bicycle S1000DBIKE-AAA-D00-00-00-00AA-130A-A


Bicycle — Normal operationprocedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-131A-A


Bicycle — Post-operationprocedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-151A-A



S1000DBIKE-AAA-D00-00-00-00AA-009A-A





No. ofpages

Applicable to

Bicycle — Servicing: Attention S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T10B


Bicycle — Servicing: Prerequisiteconcept review



Bicycle — Other procedures toclean

S1000DBIKE-AAA-D00-00-00-00AA-258A-A


Bicycle — Place on test stand S1000DBIKE-AAA-D00-00-00-00AA-330A-A


Bicycle — Standard repairprocedures

S1000DBIKE-AAA-D00-00-00-00AA-663A-A






Bicycle — Illustrated Parts Data -IPD

S1000DBIKE-AAA-D00-00-00-01AA-941A-D


Bicycle — Time limits S1000DBIKE-AAA-D05-10-00-00AA-000A-A


(Continued)


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No. ofpages

Applicable to

Bicycle — Scheduled maintenancelists

S1000DBIKE-AAA-D05-20-00-00AA-000A-A


Bicycle — Scheduled maintenancechecks

S1000DBIKE-AAA-D05-40-00-00AA-000A-A


Wheel — Description of how it ismade



Wheels — Description of how it ismade: Knowledge Check



Inner tube — Remove and install anew item



Tire — Fill with air S1000DBIKE-AAA-DA0-10-20-00AA-215A-A


Tire — Check pressure S1000DBIKE-AAA-DA0-10-20-00AA-362B-A


Front wheel — Fault reports andisolation procedures



Front wheel — Remove procedures:Interactive content - Procedure



(Continued)


S1000DBIKE-AAA-D00-00-00-00AA-009A-A





No. ofpages

Applicable to

Tire — Remove and install a newitem



Rear wheel — Detected fault S1000DBIKE-AAA-DA0-20-00-00AA-412A-A


Rear wheel — Remove procedures S1000DBIKE-AAA-DA0-20-00-00AA-520A-A


Brake system — Description of howit is made



Brake system — Manual test S1000DBIKE-AAA-DA1-00-00-00AA-341A-A


Brake pads — Clean with rubbingalcohol



Steering — Description of how it ismade



Steering — Description of how it ismade: Knowledge Check



Stem — Remove procedures S1000DBIKE-AAA-DA2-10-00-00AA-520A-A


(Continued)


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No. ofpages

Applicable to

Stem — Install procedures S1000DBIKE-AAA-DA2-10-00-00AA-720A-A


Handlebar — Remove procedures S1000DBIKE-AAA-DA2-20-00-00AA-520A-A


Handlebar — Install procedures S1000DBIKE-AAA-DA2-20-00-00AA-720A-A


Headset — Description of how it ismade



Headset — Remove procedures S1000DBIKE-AAA-DA2-30-00-00AA-520A-A


Headset — Install procedures S1000DBIKE-AAA-DA2-30-00-00AA-720A-A


Frame — Description of how it ismade



Horn — Isolated fault S1000DBIKE-AAA-DA3-10-00-00AA-411A-A


Horn — Remove and install a newitem



(Continued)


S1000DBIKE-AAA-D00-00-00-00AA-009A-A





No. ofpages

Applicable to

Drivetrain — Description of how it ismade



Chain — Oil S1000DBIKE-AAA-DA4-10-00-00AA-241A-A


Chain — Clean with chain cleaningfluid



Drive train — Correlated fault S1000DBIKE-AAA-DA4-10-00-00AA-414A-A


Gears — Description of how it ismade



Mechs — Description of how it ismade



Hubs — Clean with degreasingagent



Shifters — Description of how it ismade



(Continued)

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-022A-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Mountain bicycle

Business rules

Table of contents PageBusiness rules..............................................................................................................................................1Business rules exchange........................................................................................................................... 1General information.....................................................................................................................................1Context rules................................................................................................................................................ 1Non context rules...................................................................................................................................... 11

List of tablesTable 1 Context rules................................................................................................................................ 1

Business rules exchange

General information

Introduction to the Bike BREX DMThe Bike BREX data module has primarily been developed to

– serve as an example of how a BREX data module is meant to be used– to control and guide the continuous development of the Bike data set

The Bike BREX will be subject of continuous enhancements to ensure that each new specification issue isappropriately represented in the BREX module.

Context rules

No. [Allowed object flag] Object path/Notation name

Object use Object value[Tailoring]

Meaning

1 [2] //dmAddress/dmIdent/dmCode/@modelIdentCodeBike model identification S1000DBIKE [Closed] S1000D Bike platform

S1000DLIGHTING[Closed]

S1000D Bike light system

BRAKE [Closed] S1000D Brake system

Context: None

Table 1 Context rules


S1000DBIKE-AAA-D00-00-00-00AA-022A-D






Meaning

2 [2] //dmAddress/dmIdent/dmCode/@systemCodeSystems (Bike specific SNS) D00~D09

DA0~DA9

3 [2] //dmAddress/dmIdent/dmCode/@subSystemCodeSubsystems (Bike specific SNS) 0~9

4 [2] //dmAddress/dmIdent/dmCode/@subSubystemCodeSubsubsystems 0~9

5 [2] //dmAddress/dmIdent/dmCode/@assyCodeUnits of assembly 00~99

6 [2] //dmAddress/dmIdent/dmCode/@infoCodeBike information codes 000 [Closed] In accordance with Issue 2.3

001 [Restrictable] Title page002 [Restrictable] List of pages or data modules See also

code 00R and code 00S009 [Restrictable] Table of contents00E [Restrictable] Functional item numbers common

information repository00G [Restrictable] Parts common information repository00H [Restrictable] Zones common information repository00N [Restrictable] Support equipment common

information repository00P [Restrictable] Product Cross-reference Table (PCT)00Q [Restrictable] Conditions Cross-reference Table

(CCT)00W [Restrictable] Applicability Cross-reference Table

(ACT)00X [Restrictable] Controls and indicators common

information repository0A1 [Restrictable] Functional and/or physical areas

repository0A2 [Restrictable] !!!2009-144S1!!!

Context: None

Table 1 Context rules(Continued)


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Meaning

0A3 [Restrictable] Applicability cross reference catalog012 [Restrictable] General warnings and cautions and

related safety data018 [Closed] In accordance with Issue 2.3022 [Closed] In accordance with Issue 2.3028 [Closed] In accordance with Issue 2.3029 [Closed] In accordance with Issue 2.3040 [Closed] In accordance with Issue 2.3041 [Closed] In accordance with Issue 2.3042 [Closed] In accordance with Issue 2.3043 [Closed] In accordance with Issue 2.3056 [Closed] In accordance with Issue 2.3057 [Closed] In accordance with Issue 2.3058 [Closed] In accordance with Issue 2.3100 [Closed] In accordance with Issue 2.3121 [Closed] In accordance with Issue 2.3130 [Restrictable] Normal operation131 [Closed] In accordance with Issue 2.3151 [Closed] In accordance with Issue 2.3200 [Closed] In accordance with Issue 2.3215 [Closed] In accordance with Issue 2.3241 [Closed] In accordance with Issue 2.3251 [Closed] In accordance with Issue 2.3258 [Closed] In accordance with Issue 2.3310 [Closed] In accordance with Issue 2.3330 [Closed] In accordance with Issue 2.3341 [Closed] In accordance with Issue 2.3362 [Closed] In accordance with Issue 2.3400 [Closed] In accordance with Issue 2.3411 [Closed] In accordance with Issue 2.3412 [Closed] In accordance with Issue 2.3

Context:



S1000DBIKE-AAA-D00-00-00-00AA-022A-D






Meaning

413 [Closed] In accordance with Issue 2.3414 [Closed] In accordance with Issue 2.3520 [Closed] In accordance with Issue 2.3663 [Closed] In accordance with Issue 2.3700 [Closed] In accordance with Issue 2.3720 [Closed] In accordance with Issue 2.3913 [Closed] In accordance with Issue 2.3920 [Closed] In accordance with Issue 2.3921 [Closed] In accordance with Issue 2.3930 [Restrictable] Service Bulletin933 [Restrictable] Accomplishment instruction93A [Restrictable] Modification procedures941 [Closed] In accordance with Issue 2.3

7 [0] //descendant-or-self::orderedList[not(ancestor-or-self::description)]Sequential (numbered) lists not allowedunless in descriptive data modules

8 [0] //note[ancestor-or-self::warning]Notes are not allowed in Warnings

9 [0] //warning/orderedListOrdered lists are not allowed inWarnings

10 [0] //warning/definitionListDefinition lists are not allowed inWarnings

11 [0] //warning/randomList/listItem/randomListRandom lists must not be nested withinWarnings

12 [0] //warning/randomList/titleRandom list titles are not allowed inWarnings

13 [0] //note[ancestor-or-self::caution]Notes are not allowed in Cautions

Context: None



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Meaning

14 [0] //caution/orderedListOrdered lists are not allowed inCautions

15 [0] //caution/definitionListDefinition lists are not allowed inCautions

16 [0] //caution/randomList/listItem/randomListRandom lists must not be nested withinCautions

17 [0] //caution/randomList/titleRandom list titles are not allowed inCautions

18 [2] //@accessPanelTypeValueType of access panel accpnl01 [Closed] Access is a door

accpnl02 [Closed] Access is a panelaccpnl03 [Closed] Access is an electrical panel

19 [2] //acronym/@acronymtypeType of acronym or abbreviation at01 [Closed] Acronym (Candidate for list of

abbreviations) - Default valueat02 [Closed] Term (Candidate for list of terms)at03 [Closed] Symbol (Candidate for list of symbols)at04 [Closed] Spec (Candidate for list of applicable

specs)

20 [2] //dialog/@cancelCaptionCaption for dialog cancel function ca01 [Closed] Sets the caption to "CANCEL"

ca02 [Closed] Sets the caption to "ABORT"ca03 [Closed] Sets the caption to "NO"ca04 [Closed] Sets the caption to "END"ca05 [Closed] Sets the caption to "QUIT"

21 [2] //security/@securityClassificationSecurity classification 01 [Closed] 1 (lowest level of security

classification, eg Unclassified)

Context: None



S1000DBIKE-AAA-D00-00-00-00AA-022A-D






Meaning

22 [2] //security/@commercialClassificationCommercial security classification cc51 [Closed] Open

23 [2] //caption/@colourCaption color co00 [Closed] None

co01 [Closed] Greenco02 [Closed] Amberco03 [Closed] Yellowco04 [Closed] Redco07 [Closed] Whiteco08 [Closed] Greyco09 [Closed] Clear - Default valueco51 [Closed] Blue (used on Bike Computer Display)

24 [0] //commentPriority[not(attribute::commentPriorityCode)]Priority level of a comment required

25 [2] //@commentPriorityCodePriority level of a comment cp01 [Closed] Routine

cp02 [Closed] Emergencycp03 [Closed] Safety critical

26 [0] //crewMember[not(attribute::crewMembertype)]Type of crew member required for drillor procedural step

27 [2] //@crewMembertypeType of crew member cm01 [Closed] All

cm51 [Closed] Bike ridercm52 [Closed] Bike technician

28 [0] //crewDrill/@drillTypeTypes of aircrew drills do not apply tothe BikeDMs

29 [2] //emphasis/@emphasisTypeType of emphasis em01 [Closed] Bold - Default value

Context: None



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Meaning

em02 [Closed] Italic (only for legacy data, see Chap3.9.1)

em03 [Closed] Underline (only for legacy data, seeChap 3.9.1)

em04 [Closed] Overline (only for marking vectors)em05 [Closed] Strikethrough (not to be used to mark

deleted text)

30 [2] //installationLocation/@installationLocationTypeType of install location instloctyp02 [Closed] Section

instloctyp03 [Closed] Stationinstloctyp04 [Closed] Water lineinstloctyp05 [Closed] Buttock lineinstloctyp60 [Closed] Frame

31 [2] //maintLevel/@maintLevelCodeMaintenance level ml01 [Closed] Level 1 (home)

ml02 [Closed] Level 2 (authorized workshop)

32 [2] //@itemOriginatorOrigin of equipment/harness/wire orig01 [Closed] Manufacturer

orig02 [Closed] Vendororig03 [Closed] Partner

33 [2] //randomList/@listItemPrefixPrefix of 'randomList' items, limited tothree variants

pf01 [Closed] Simple (No prefix, only indent)pf02 [Closed] Unorder (Depending on list level, prefix

with short dash for first level, bullet forsecond, and short dash for third level -ISOpub: bull, dash) - Default value

pf03 [Closed] Dash (short dash - ISOpub: dash)

34 [2] //inlineSignificantData/@significantParaDataTypeParagraph significant data type psd01 [Closed] Ammunition

psd02 [Closed] Instruction dispositionpsd03 [Closed] Lubricant

Context: None



S1000DBIKE-AAA-D00-00-00-00AA-022A-D






Meaning

psd04 [Closed] Maintenance levelpsd05 [Closed] Manufacturer codepsd06 [Closed] Manufacturers recommendationpsd07 [Closed] Modification codepsd08 [Closed] Qualification codepsd09 [Closed] Training levelpsd10 [Lexical] Control or Indicator value

35 [2] //quantity/@quantityTypeQuantity data type qty01 [Closed] Length

qty02 [Closed] Priceqty03 [Closed] Temperatureqty04 [Closed] Timeqty05 [Closed] Torque valueqty06 [Closed] Voltageqty07 [Closed] Volumeqty08 [Closed] Mass

36 [2] //dialog/@resetCaptionCaption for dialog reset caption re01 [Closed] Sets the caption to "RESET"

re02 [Closed] Sets the caption to "CLEAR"

37 [2] //commentResponse/@responseTypeType of response to a comment rt01 [Closed] Accepted

rt02 [Closed] Pendingrt03 [Closed] Partially acceptedrt04 [Closed] Rejected

38 [2] //@skillLevelCodePersonnel skill level sk01 [Closed] Basic

sk02 [Closed] Intermediatesk03 [Closed] Advanced

Context: None



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Meaning

39 [2] //@submitCaptionCaption for dialog submit function ok01 [Closed] Sets the caption to "OK"

ok02 [Closed] Sets the caption to "SUBMIT"ok03 [Closed] Sets the caption to "YES"ok04 [Closed] Sets the caption to "CONTINUE"ok05 [Closed] Sets the caption to "EXIT"

40 [2] //supervisorLevel/@supervisorLevelCodeSupervisor level sl01 [Closed] Low

sl02 [Closed] Low intermediatesl03 [Closed] High intermediatesl04 [Closed] High

41 [2] //@taskCodeTask code taskcd01 [Closed] Detailed inspection (DET)

taskcd02 [Closed] Discard (DIS)taskcd03 [Closed] Functional Check (FNC)taskcd04 [Closed] General visual inspection (GVI)taskcd05 [Closed] Lubrication (LUB)taskcd06 [Closed] Operational check (OPC)taskcd07 [Closed] Restoration (RST)taskcd08 [Closed] Servicing (SVC)taskcd09 [Closed] Visual check (VCK)

42 [2] //limitType/@limitUnitTypeLimit type lt01 [Closed] Time between overhaul

lt02 [Closed] Hard timelt03 [Closed] Since last maintenancelt04 [Closed] Out time limitlt05 [Closed] On conditionlt06 [Closed] Check maintenancelt07 [Closed] Functional check

Context: None



S1000DBIKE-AAA-D00-00-00-00AA-022A-D






Meaning

43 [2] //threshold/@thresholdUnitOfMeasureUnit of measurement for the thresholdinterval

th03 [Closed] Monthsth04 [Closed] Weeksth05 [Closed] Yearsth06 [Closed] Daysth11 [Closed] Shop visitsth12 [Closed] Auxiliary power unit changeth14 [Closed] Wheel changeth35 [Lexical] kilometer

44 [2] //sourceType/@sourceTypeCodeindicates the type of source stc51 [Closed] fec

stc52 [Closed] sample

45 [2] //sourceType/@sourceCriticalityindicates the impact of not complyingwith the requirement

sc55 [Closed] Evident, Safetysc56 [Closed] Evident, operationalsc57 [Closed] Evident, Economicsc58 [Closed] Hidden, Safetysc59 [Closed] Hidden, Non-Safety

46 [2] //verbatimText/@verbatimStyleVerbatim style vs01 [Closed] Generic verbatim

vs02 [Closed] Filenamevs11 [Closed] XML/SGML markupvs12 [Closed] XML/SGML element namevs13 [Closed] XML/SGML attribute namevs14 [Closed] XML/SGML attribute valuevs15 [Closed] XML/SGML entity namevs16 [Closed] XML/SGML processing instructionvs21 [Closed] Program promptvs22 [Closed] User input

Context: None



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Meaning

vs23 [Closed] Computer outputvs24 [Closed] Program listingvs25 [Closed] Program variable namevs26 [Closed] Program variable valuevs27 [Closed] Constantvs28 [Closed] Class namevs29 [Closed] Parameter name

47 [2] //@quantityUnitOfMeasureQuantity data unit of measure - forfurther information refer to Chap 3.9.6.2and the corresponding xml table

Context: None


Non context rulesBike data modules must be reviewed and approved by EPWG before publishing.The Bike data set must contain examples of how to apply constructs and principles representing various levelsof concept sophistication.

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-00PA-DApplicable to:All


Mountain bicycle

Products cross-reference table

Table of contents PageProducts cross-reference table................................................................................................................. 1References................................................................................................................................................... 1Product cross-reference table................................................................................................................... 1

List of tablesTable 1 References....................................................................................................................................1Table 2 List of product instances............................................................................................................ 1

References

Data module / Technical publication Title

None

Table 1 References

Product cross-reference table

Identifier Type Value

Product instanceserialno Product attribute 1B070643model Product attribute Brook trekkerversion Product attribute Mk9versrank Product attribute 2SB-S001 Condition Pre

Product instanceserialno Product attribute 1B070644model Product attribute Brook trekkerversion Product attribute Mk9versrank Product attribute 1SB-S001 Condition Post

Product instanceserialno Product attribute 1B070701

Table 2 List of product instances


S1000DBIKE-AAA-D00-00-00-00AA-00PA-D


Applicable to:All

Identifier Type Value

model Product attribute Mountain stormversion Product attribute Mk1versrank Product attribute 1SB-S001 Condition Pre

Table 2 List of product instances(Continued)

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-00QA-DApplicable to:All


Mountain bicycle

Conditions cross-reference table

Table of contents PageConditions cross-reference table.............................................................................................................. 1References................................................................................................................................................... 1Condition cross-reference table................................................................................................................ 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Common types of conditions..................................................................................................... 1Table 3 Conditions.....................................................................................................................................2Table 4 Incorporation.................................................................................................................................2

References


None

Table 1 References

Condition cross-reference table

Name

Id

Description Data type

Value pattern

Values

Service bulletinSB

Generic service bulletin type String PREPOST-001~POST-999

generic Boolean conditionBoolean

Boolean condition True|False

Table 2 Common types of conditions


S1000DBIKE-AAA-D00-00-00-00AA-00QA-D


Applicable to:All

Name

Displayname (Id)

Conditiontype

Alias

Description

Prompt

Data type

Valuepattern

References

Condition ref group

Dependency

Service bulletinS001 - Chainguard

(SB-S001)

SB Service bulletin S001for the installation ofthe chain guard


Values:POST-001Applic:SB 1

tour finished(tourFinished)

Boolean finished tour

Table 3 Conditions

Id Issue No. References Date Status

SB-S001 00 S1000DBIKE-AAA-DA0-20-00-00AA-520A-A 2007-07-31 Incorporated

SB-S001 01 S1000DBIKE-AAA-DA0-20-00-00AA-520A-A No effect

Table 4 Incorporation

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-00WA-DApplicable to:All


Mountain bicycle

Applicability cross-reference table

Table of contents PageApplicability cross-reference table............................................................................................................ 1References................................................................................................................................................... 1Applicability cross-reference table............................................................................................................ 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Product attribute list.................................................................................................................... 1

References


None

Table 1 References


Conditions cross-reference table: S1000DBIKE-AAA-D00-00-00-00AA-00QA-DProducts cross-reference table: S1000DBIKE-AAA-D00-00-00-00AA-00PA-D

Name

Display name (Id)


Value pattern

Values

Serial numberSN (serialno)

Serial number (etched on theframe)

Type(type)

Type of bike

Model(model)

Model of the bike .* Brook trekker|Mountainstorm

Version(version)

Version of the bike Mk(1|9) Mk1|Mk9

Version rankseries (versrank)

Version rank Integer 1~3

Table 2 Product attribute list


S1000DBIKE-AAA-D00-00-00-00AA-00WA-D


Applicable to:All

Name

Display name (Id)


Value pattern

Values

Brake Serial numberBSN (brakeSerialno)

Serial number on the brake

External product attribute

Brake model - Themodel of the brake in abike (brakeModel)

Table 2 Product attribute list(Continued)

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-0A3A-DApplicable to:All


Mountain bicycle

Applicability cross-reference table catalog

Table of contents PageApplicability cross-reference table catalog.............................................................................................. 1References................................................................................................................................................... 1Applicability cross-reference table............................................................................................................ 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Applicability cross-reference table references.........................................................................1Table 3 Product definition relationships..................................................................................................1

References


None

Table 1 References


Data module Title

S1000DBIKE-AAA-D00-00-00-00AA-00WA-DBRAKE-AAA-D00-00-00-00AA-00WA-D

Table 2 Applicability cross-reference table references

Identifier Type Values Data module Associationtype

brakeSerialNo Product attribute S1000DBIKE-AAA-D00-00-00-00AA-00WA-DserialNo Product attribute BRAKE-AAA-D00-00-00-00AA-00WA-D Alias

brakeModel Product attribute S1000DBIKE-AAA-D00-00-00-00AA-00WA-Dmodel Product attribute BRAKE-AAA-D00-00-00-00AA-00WA-D External

reference

Table 3 Product definition relationships

End of data module

UNCLASSIFIEDMY COMCLASS

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Bicycle

Time limits

Table of contents PageTime limits.................................................................................................................................................... 1References................................................................................................................................................... 1Time limits.................................................................................................................................................... 1

List of tablesTable 1 References....................................................................................................................................1

References


None

Table 1 References

Time limits

Ident Equipment Qty Time limits Applicability

001 BicyclePart: KZ555/PN Bicycle-001

1 EA Type: Functional check1 D ± 1Type: On condition1 D

Mountain bicycle and(Mountain storm Mk1 orBrook trekker Mk9)

002 Brake padsPart: KT444/PN BR-PADS-001

4 EA Category: Cat 1Type: On condition1 M


003 ChainPart: KZ555/PN Ch-001

Type: On condition1 M


004 Hub bearingsPart: KZ555/PN HB-001

2 EA Category: Cat 1Type: Check maintenance6 M ± 1


End of data module


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Bicycle

Scheduled maintenance lists

List of tasksTask ident Description

001 To do the pre-ride checks002 To do the post-ride maintenance003 Clean brake pads004 Clean the chain005 Clean the hub bearings

Table of contents PageScheduled maintenance lists.....................................................................................................................1References................................................................................................................................................... 2Task ident: 001............................................................................................................................................2Task ident: 002............................................................................................................................................5Task ident: 003............................................................................................................................................7Task ident: 004............................................................................................................................................9Task ident: 005......................................................................................................................................... 11

List of tablesTable 1 References....................................................................................................................................2Table 2 Required conditions.................................................................................................................... 2Table 3 Required persons........................................................................................................................ 3Table 4 Support equipment......................................................................................................................3Table 5 Consumables, materials and expendables.............................................................................. 3Table 6 Spares...........................................................................................................................................3Table 7 Required conditions.................................................................................................................... 5Table 8 Required persons........................................................................................................................ 5Table 9 Support equipment......................................................................................................................5Table 10Consumables, materials and expendables.............................................................................. 5Table 11Spares...........................................................................................................................................5Table 12Required conditions.................................................................................................................... 7Table 13Required persons........................................................................................................................ 7Table 14Support equipment......................................................................................................................7Table 15Consumables, materials and expendables.............................................................................. 7Table 16Spares...........................................................................................................................................7Table 17Required conditions.................................................................................................................... 9Table 18Required persons........................................................................................................................ 9Table 19Support equipment......................................................................................................................9Table 20Consumables, materials and expendables.............................................................................. 9Table 21Spares.........................................................................................................................................10Table 22Required conditions.................................................................................................................. 11Table 23Required persons...................................................................................................................... 11

S1000DBIKE-C3002-LOAP1-00 UNCLASSIFIEDMY COMCLASS

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S1000DBIKE-AAA-D05-20-00-00AA-000A-A




Table 24Support equipment....................................................................................................................11Table 25Consumables, materials and expendables............................................................................11Table 26Spares.........................................................................................................................................12

References


S1000DBIKE-AAA-D00-00-00-00AA-121A-A Bicycle — Pre-operation procedures (crew)S1000DBIKE-AAA-D00-00-00-00AA-151A-A Bicycle — Post-operation procedures (crew)S1000DBIKE-AAA-DA0-20-00-00AA-520A-A Rear wheel — Remove proceduresS1000DBIKE-AAA-DA1-10-00-00AA-251A-A Brake pads — Clean with rubbing alcoholS1000DBIKE-AAA-DA4-10-00-00AA-251B-A Chain — Clean with chain cleaning fluid

Table 1 References

Task ident: 001Task code: ................................................................General visual inspection (GVI)Worthiness limitation: ..............................................RecommendedReduced maintenance: ...........................................NoSkill type: .................................................................. Airframe (AIRPL)Task description: ..................................................... To do the pre-ride checks

Requirement sourceSource of requirement: ........................................... MRBApproval: ...................................................................ap01Source type

Code: ................................................................ stc51Source criticality: .............................................sc55

Preliminary requirements

Required conditions

Action / Condition Data module / Technical publication

None

Table 2 Required conditions


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Required persons

Person Category Skill level Trade/Trade code Estimated time

Man A Basic user Operator 0,3 h

Table 3 Required persons

Support equipment

Name Identification/Reference Quantity Remark

Tire pressure gauge Part: KZ666/PN BSK-TLST-001-01

1 EA

Specialist toolset Part: KZ666/PN BSK-TLST-001

1 EA

Table 4 Support equipment

Consumables, materials and expendables


General lubricant Part: KZ222/PN LL-001 As required

Table 5 Consumables, materials and expendables

Spares


None

Table 6 Spares

Safety conditionsNone

ReferencesS1000DBIKE-AAA-D00-00-00-00AA-121A-A

Equipment– Bicycle

Part: KZ555/PN Bicycle-001


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LimitPerform onceInterval: 1 D ± 1Inspection type: Daily


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Task ident: 002Worthiness limitation: ..............................................RecommendedReduced maintenance: ...........................................NoTask description: ..................................................... To do the post-ride maintenance


Required conditions


None


Required persons




Support equipment



1 EA






Spares


None

Table 11 Spares


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ReferencesS1000DBIKE-AAA-D00-00-00-00AA-151A-A

Equipment– Bicycle

Part: KZ555/PN Bicycle-001

LimitOn conditionCondition: Dirty1 D ± 1Inspection type: Daily


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Task ident: 003Worthiness limitation: ..............................................RecommendedReduced maintenance: ...........................................YesTask description: ..................................................... Clean brake pads


Required conditions


None


Required persons




Support equipment


None




Rubbing alcohol Part: KZ222/PN LL-002 As required


Spares


None

Table 16 Spares


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S1000DBIKE-AAA-D05-20-00-00AA-000A-A





ReferencesS1000DBIKE-AAA-DA1-10-00-00AA-251A-A

Equipment– Brake pads

Part: KT444/PN BR-PADS-001

LimitPerform onceInspection type: MonthlyLimit range:

from: 1 Mto: 1 M


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Task ident: 004Worthiness limitation: ..............................................RecommendedReduced maintenance: ...........................................YesTask description: ..................................................... Clean the chain


Required conditions


None


Required persons




Support equipment


Stiff bristle brush Part: KZ666/PN BSK-TLST-001-02

1 EA

Chain cleaning fluid Part: KZ222/PN LL-003 As requiredChain cleaning tool Part: KZ666/PN BSK-

TLST-001-031 EA




Floor covering Part: / As requiredGeneral lubricant Part: KZ222/PN LL-001 As required



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S1000DBIKE-AAA-D05-20-00-00AA-000A-A




Spares


None

Table 21 Spares


ReferencesS1000DBIKE-AAA-DA4-10-00-00AA-251B-AS1000DBIKE-AAA-D00-00-00-00AA-121A-A

Equipment– Chain

Part: KZ555/PN Ch-001

LimitPerform onceCondition: Dirty1 MInspection type: MonthlyTrigger event:

S1000DBIKE-AAA-D00-00-00-00AA-121A-A


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Task ident: 005Worthiness limitation: ..............................................RecommendedReduced maintenance: ...........................................NoTask description: ..................................................... Clean the hub bearings

Requirement sourceSource of requirement: ........................................... MRBReference: ................................................................ D6-1234Source type

Code: ................................................................ stc52Source criticality: .............................................sc59


Required conditions


Rear wheel removed S1000DBIKE-AAA-DA0-20-00-00AA-520A-A


Required persons


Man B Supervisor Advanced Bicycle mechanic 0,8 hMan A Basic user Operator 0,3 h


Support equipment



1 EA




Degreasing agent Part: KZ222/PN LL-004 As required



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S1000DBIKE-AAA-D05-20-00-00AA-000A-A





General grease Part: KZ222/PN LL-005 As required

Table 25 Consumables, materials and expendables (Continued)

Spares


None

Table 26 Spares


Equipment– Hubs

Part: KZ555/PN HB-002

SuperviseSupervisor level: ...................................................... Low

LimitPerform once6 MInspection type: 6 MonthlyLimit range:

from: 6 M ± 1

End of data module


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Bicycle

Scheduled maintenance checks

Table of contents PageScheduled maintenance checks............................................................................................................... 1References................................................................................................................................................... 1Inspection definitions...................................................................................................................................1


References


S1000DBIKE-AAA-D00-00-00-00AA-121A-A Bicycle — Pre-operation procedures (crew)

Table 1 References

Inspection definitions

Limits

No. Task References

Applicability

• On conditionCondition: Pre-ride1 W ± 1Inspection type: PreLimit range:

from: 1 W ± 1

001 Inspect BrakesTo do an inspection of the brakes

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

002 Inspect brakes installationTo do an inspection of the brakesinstallation

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

003 Check Tire PressureTo do a check of the tire pressure

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

004 Inspect wheel conditionTo do an inspection of the wheelcondition

S1000DBIKE-AAA-D00-00-00-00AA-121A-A


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S1000DBIKE-AAA-D05-40-00-00AA-000A-A




Limits

No. Task References

Applicability

005 Check headset bearingsTo do a check of the headset bearings

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

006 Carry out chain checksTo do a check of the chain

S1000DBIKE-AAA-D00-00-00-00AA-121A-A

(Continued)

End of data module



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Bicycle

Description of how it is made

Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Physical description of a bicycle............................................................................................... 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Bicycle parts.................................................................................................................................2

List of figuresFig 1 Complete bicycle......................................................................................................................... 2

References


None

Table 1 References

Description

1 Physical description of a bicycleA bicycle (refer to Fig 1) is a frame and a number of movable components with mechanical partsthat are completely open. There are no covers or sheet metal panels that prevent access to themechanical parts. Thus, you can disassemble the different components of a bicycle (refer toFig 1 [0]) to do:

– an inspection– a maintenance task– a repair task


S1000DBIKE-AAA-D00-00-00-00AA-041A-A




ICN-S1000DBIKE-AAA-D000000-0-U8025-00536-A-04-1Fig 1 Complete bicycle

The parts that you can immediately identify on a bicycle are given in Table 1.

Item Refer to Definition

Frame Fig 1 [9] A bicycle frame is made of metal tubes thatare welded together.

Wheels The wheels include these parts:

– Hub– Spokes– Metal rim– Rubber tire

– Rear wheelFig 1 [7]

– Front wheelFig 1 [3]

Table 2 Bicycle parts



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Item Refer to Definition

Seat and seat post Fig 1 [8] These install into the seat tube with amechanism you can use to change theheight.

Handle bars Fig 1 [11] A horizontal bar that attaches to the stemwith grips at the ends that attach to thebrake levers and the shifters.

Handle bar stem Fig 1 [10] This attaches the handle bar to the steeringtube (head set).

Cranks Fig 1 [5] A lever that extends from the bottom of thebracket to the pedal.

Pedals Fig 1 [4] The two platforms for the feet that attach tothe crank.

Chain Fig 1 [6] A circular set of links that connect the chainring to the cogs on the freewheel.

Gears Fig 1 [2] The gears include:

– Front chain ring– Rear freewheel– Front and the rear derailleur– Shift lever on the handle bars– Cables

Brakes Fig 1 [1] The brakes include:

– Actuators on the handlebars– Brake cable– Brake callipers– Brake pads

Table 2 Bicycle parts (Continued)

End of data module



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Bicycle

Description of function

Table of contents PageDescription of function................................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Functional description of a bicycle............................................................................................1


References


S1000DBIKE-AAA-DA0-00-00-00AA-041A-A Wheel — Description of how it is madeS1000DBIKE-AAA-DA1-00-00-00AA-041A-A Brake system — Description of how it is madeS1000DBIKE-AAA-DA2-10-00-00AA-520A-A Stem — Remove proceduresS1000DBIKE-AAA-DA2-10-00-00AA-720A-A Stem — Install proceduresS1000DBIKE-AAA-DA2-20-00-00AA-520A-A Handlebar — Remove proceduresS1000DBIKE-AAA-DA2-20-00-00AA-720A-A Handlebar — Install proceduresS1000DBIKE-AAA-DA3-00-00-00AA-041A-A Frame — Description of how it is madeS1000DBIKE-AAA-DA4-10-00-00AA-251B-A Chain — Clean with chain cleaning fluidS1000DBIKE-AAA-DA5-00-00-00AA-041A-A Gears — Description of how it is madeS1000DBIKE-AAA-DA5-10-00-00AA-041A-A Mechs — Description of how it is madeS1000DBIKE-AAA-DA5-30-00-00AA-041A-A Shifters — Description of how it is made

Table 1 References

Description

1 Functional description of a bicycleBelow is a list of the different bicycle components and a functional description of them.Frame The frame is the skeleton of the bicycle. Refer to

S1000DBIKE-AAA-DA3-00-00-00AA-041A-A for afunctional description of the frame system.

Wheel The wheel is the point of contact between the bicycleand the road for the bicycle to have movement. Refer


S1000DBIKE-AAA-D00-00-00-00AA-042A-A




to S1000DBIKE-AAA-DA0-00-00-00AA-041A-A for afunctional description of the wheel.

Spokes The spokes are thick wires with tension applied thatconnect the hub to the rim. You can adjust the tensionwith the nipple on the rim side.

Hub The hub attaches to the center of the wheel where theaxle and the bearings are.

Metal rim The metal rim is a metal ring that has a U-shaped crosssection to hold the spokes on the inner side and the tireon the outer side.

Seat The Seat, which is also known as the 'saddle', is used asthe support platform for the person to sit on the bicycle.

Seat post The Seat post is used as a support post for the seat andto change the height of the seat for the rider.

Handle bar The handle bar is a horizontal bar with handles oneach end. The handle bar is a steering mechanism thatthe rider uses to change the direction of the bicycle.The brake levers are also on the handle bar. Referto S1000DBIKE-AAA-DA2-20-00-00AA-720A-A forinformation on how to install the handle bar. Referto S1000DBIKE-AAA-DA2-20-00-00AA-520A-A forinformation on removing the handlebar.

Handle bar stem The handle bar stem (the stem) attaches the handlebar to the steering tube. Refer to S1000DBIKE-AAA-DA2-10-00-00AA-720A-A for information onhow to install a stem. Refer to S1000DBIKE-AAA-DA2-10-00-00AA-520A-A for information on how toremove the stem.

Brake levers When you operate the brake lever, the brake pads moveagainst the wheel to decrease the speed. The brakelever on the left side operates the front brake. The brakelever on the right side operates the rear brake.

Brakes When you operate the brakes, the brake pad movesagainst the wheel to decrease the speed of the bicycle.Refer to S1000DBIKE-AAA-DA1-00-00-00AA-041A-Afor a description of the braking system.

Shifters The shifters are the mechanisms that you use to changethe gears on the bicycle. There are 7 different types ofshifters that have been developed over the years, butthey all have the same functionality. When you operatethe shifters, they pull the control cable to move thederailleur towards a larger diameter chain ring. Theshifters can also loosen the cable to let the derailleurmove towards a smaller diameter chain ring. Refer toS1000DBIKE-AAA-DA5-30-00-00AA-041A-A for afunctional description of the shifters.



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Crank The crank moves the power to the chain rings when thepedals operate.

Pedals The pedals move the force of movement from the feet tothe cranks.

Chain The chain moves the power from the chain rings to thecogs on the freewheel. Refer to S1000DBIKE-AAA-DA4-10-00-00AA-251B-A for the procedure on how toclean the chain.

Gears The gears have different mechanisms that functiontogether to change the speed of the bicycle. Thesemechanisms include:

the sprocketsthe chainthe derailleur

Refer to S1000DBIKE-AAA-DA5-00-00-00AA-041A-Afor a functional description of the gear system.

Chain rings The chain rings (also known as the 'chain wheel') pull onthe chain when the cranks turn.

Derailleur A derailleur moves the chain from one sprocket toanother to change the gears. There are two differenttypes of derailleur, the front and the rear. The highestratio (highest gear) is when the chain is on the largestsprocket on the front and the smallest at the rear. Toget the lowest gear, the smallest sprocket is at the frontand the largest at the rear. Refer to S1000DBIKE-AAA-DA5-10-00-00AA-041A-A for a functional description ofthe derailleur system.

End of data module



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Bicycle

Description attributed to crew

Table of contents PageDescription attributed to crew....................................................................................................................1References................................................................................................................................................... 11 Introduction...................................................................................................................................12.1 Controls.........................................................................................................................................12.2 Steering.........................................................................................................................................12.3 Shifters.......................................................................................................................................... 22.4 Brakes........................................................................................................................................... 22.5 Pedals........................................................................................................................................... 2

List of tablesTable 1 References....................................................................................................................................1Table 2 shifter correlation......................................................................................................................... 2Table 3 brake lever correlation................................................................................................................ 2

References


S1000DBIKE-AAA-DA5-30-00-00AA-041A-A Shifters — Description of how it is made

Table 1 References

1 IntroductionData about the bicycle and its control system is given in this document. This data will help youoperate the bicycle.

22.1 Controls

Data about the controls that follow is given in this document:

– Para 2.2– Para 2.3– Para 2.4– Para 2.5

2.2 SteeringThe handlebars are used to steer the bike. They are at the front of the bicycle. You hold one of thehandlebar grips with each hand and move the handle bar to change the direction of the bike.


S1000DBIKE-AAA-D00-00-00-00AA-043A-A




2.3 ShiftersThe gears control the ratio of pedal rotation to wheel rotation. You can change this with the shiftersS1000DBIKE-AAA-DA5-30-00-00AA-041A-A . The shifters are on the handlebar.

A description of the two Table 2 follows.

Shifter Location Affected Gears

Left The buttons on the left shifter changes the gears on thefront derailleur.

Right The buttons on the right shifter changes the gears on therear derailleur.

Table 2 shifter correlation

2.4 Brakes

WARNINGIf you operate the front brake without the rear brake you can cause a crash.

You can decrease the speed of the bike with the brakes. You operate the brakes with the brakelevers on the handlebar.

A description of the Table 3 follows.

Brake Lever Location Affected Brake

Left This lever operates the front brake.Right This lever operates the rear brake.

Table 3 brake lever correlation

2.5 PedalsThe ci-0004 are at the bottom of the seat tube. You operate the ci-0004 to move the bicycleforward.

End of data module


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S1000DBIKE-AAA-DA0-00-00-00AA-041A-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Wheel


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 The bicycle wheel........................................................................................................................11.1 Spokes.......................................................................................................................................... 31.2 Wheel rim......................................................................................................................................31.3 Tube and tire................................................................................................................................5


List of figuresFig 1 Parts of the wheel....................................................................................................................... 2Fig 2 The tire and rim........................................................................................................................... 4Fig 3 Valve..............................................................................................................................................6

References


None

Table 1 References

Description

1 The bicycle wheelThe wheel (refer to Fig 1) of a bicycle is a complex structure. The wheel assembly has these parts:

the tirethe tubethe spokesthe spoke nipplesthe valvethe hub

On their own, the individual components are not very strong. But, when they are installed together,the components make the complete wheel (refer to Fig 1). The complete wheel is resistant toalmost any type of heavy loads and operation.


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ICN-S1000DBIKE-AAA-DA00000-0-U8025-00504-A-04-1Fig 1 Parts of the wheel


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1.1 SpokesThe spokes go out from the hub and go across and below each other. The spoke nipples attachthe spokes to the rim with the threads on the end of the spokes. You can use the spoke nipples toadjust the tension of the spokes. The tension on each of the spokes must be equal.

1.2 Wheel rimThe rim (refer to Fig 2) of the wheel has a lining of rim tape. This tape protects the tube fromdamage that the rough edges on the spoke nipples can cause.


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ICN-S1000DBIKE-AAA-DA00000-0-U8025-00504-B-04-1Fig 2 The tire and rim


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1.3 Tube and tireThe tube and the tire install on the rim. The sidewalls of the tire have markings on them. Thesewhich are used to indicate the correct direction of rotation. The markings also make sure the tireinstalls on the rim and that the directional arrows points in the correct direction. You install thetube into the tire before you inflate it. The tube has a valve (refer to Fig 3) which you put throughthe hole in the rim. This valve (refer to Fig 3) is used to inflate the tube and the tire to the correctpressure. A dust cap installs on the valve (refer to Fig 3) to prevent damage that dust and debriscan cause.


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ICN-S1000DBIKE-AAA-DA00000-0-U8025-00505-A-04-1Fig 3 Valve

End of data module


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Brake system


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Brake system............................................................................................................................... 11.1 Cantilever brake...........................................................................................................................11.2 Brake pads................................................................................................................................... 41.3 Brake lever................................................................................................................................... 6


List of figuresFig 1 Cantilever brake with straddle cable........................................................................................ 3Fig 2 Exploded diagram of a brake.................................................................................................... 5Fig 3 Typical components of a mountain bicycle lever.................................................................... 7

References


None

Table 1 References

Description

1 Brake systemThe most important part of the bicycle is the brake system. Only a minimum maintenance of thebrake system is necessary. But, when a problem does occur, make sure you to do the necessarymaintenance as quickly as possible. If you do not do this the bicycle will be dangerous to use.

There are nine different types of brake systems. The one found on most bicycles is the cantileverbrake (refer to Para 1.1).

1.1 Cantilever brakeThe brake system (refer to Fig 1) has these primary components:

the brake lever (refer to Para 1.3)the brake cablethe brake arm


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the brake clamp (also known as callipers)the brake pads (refer to Para 1.2)


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00512-A-04-1Fig 1 Cantilever brake with straddle cable


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A cable that goes from the brake levers on the handlebars pulls the two levers on the brakestogether. This presses the brake pads against the outer rim of the wheel, which decreases thespeed of the bicycle.

1.2 Brake padsThere are four brake pads (refer to Fig 2) on the bicycle. Two are found on the front wheel and twoon the rear wheel. The brake pads are made out of hard wearing rubber. The pads press againstthe rim of the wheel to cause friction when the you operate the brake levers.


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00513-A-04-1Fig 2 Exploded diagram of a brake


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1.3 Brake leverThe brake levers (refer to Fig 3) are easily damaged. The lever is installed in the mount. A clampbolt holds the mount. This bolt is not visible because it is found in the mount. The lever turns on alever pivot bolt. The adjuster lock nut holds the brake cable. This lock nut adjusts the tension of thecable.


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00514-A-04-1Fig 3 Typical components of a mountain bicycle lever


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The left brake lever holds the brake pads on the front wheel and the right brake pads hold thebrakes on the rear wheel.

End of data module


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Steering


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Steering.........................................................................................................................................11.1 Handlebar..................................................................................................................................... 21.2 Headset.........................................................................................................................................21.3 Stem.............................................................................................................................................. 2


References


S1000DBIKE-AAA-DA2-10-00-00AA-520A-A Stem — Remove proceduresS1000DBIKE-AAA-DA2-10-00-00AA-720A-A Stem — Install proceduresS1000DBIKE-AAA-DA2-20-00-00AA-520A-A Handlebar — Remove proceduresS1000DBIKE-AAA-DA2-20-00-00AA-720A-A Handlebar — Install proceduresS1000DBIKE-AAA-DA2-30-00-00AA-041A-A Headset — Description of how it is madeS1000DBIKE-AAA-DA2-30-00-00AA-520A-A Headset — Remove proceduresS1000DBIKE-AAA-DA2-30-00-00AA-720A-A Headset — Install procedures

Table 1 References

Description

1 SteeringThe steering on the bike is what enables the bike to manoeuvre in a given direction during travel.The steering system on the bike is made of three parts, they are:

Para 1.1 The handlebarPara 1.2 The headsetPara 1.3 The stem


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1.1 HandlebarThis consists of a horizontal bar attached to the stem with handgrips at the end. Brake levers andshifters are also attached to this bar although they do not have any part in the steering mechanism.The handlebars manoeuvrability is a sideways swivelling action. The handlebars themselves donot provide this swivelling, the headset (also known as the steering tube) is the mechanism thatenables the handlebars to swivel.

1.2 HeadsetThis mechanism is situated in front of the frame and connects the front fork to the stem andhandlebars. The headset allows the handlebars to swivel left and right for steering purposes.

For a full description of the headset, refer to S1000DBIKE-AAA-DA2-30-00-00AA-041A-A .

1.3 StemThe stem is a piece that attaches the handlebar to the steering tube. Basically the stem is justa threaded stem bolt situated inside the steerer tube and is what attaches the handlebars to theheadset.

End of data module


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Headset


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Headset.........................................................................................................................................1


List of figuresFig 1 Headset.........................................................................................................................................3

References


None

Table 1 References

Description

1 HeadsetThe headset (refer to Fig 1) is a pair of bearings on the two ends of the head tube of the frame.These bearings permit the fork to turn rearward and forward (for example, to let the rider turn thehandlebars for the steering).

The headset (refer to Fig 1) includes the parts that follow:

The bearing races that push into the head tubea bearing race that pushes on the fork steerer tubean adjustable upper racetwo sets of ball bearings

A headset has cups that are pushed into the head tube and a ring on the fork. All three must befully parallel. It is usually necessary to remove rough paint to get all three fully parallel.

The upper race installs onto the steerer tube with a thread. A locknut is used to safety the upperrace.

A clamp bolt holds the stem to the steerer tube.


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The fourth remaining bearing race is part of a nut that installs on the threaded top end of the fork.This is done after you install it in the head tube. It is sometimes necessary for some headsetsto have more thread at the top of the head tube. If the fork is too long, the spacer rings can beinstalled. If it is too short, there is a limit to the number of headsets you can use.

For an illustration of the parts of the headset (refer to Fig 1).


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ICN-S1000DBIKE-AAA-DA23000-0-U8025-00533-A-04-1Fig 1 Headset

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Frame


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 The bicycle frame........................................................................................................................1


List of figuresFig 1 Welded frame joints.................................................................................................................... 2Fig 2 Frame............................................................................................................................................ 3

References


None

Table 1 References

Description

1 The bicycle frameThe frame is the skeleton, the primary part of your bicycle. Its structure makes the bicycle resistantto large forces.

The initial frames (refer to Fig 1) were tubes of aluminum or steel welded together.


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ICN-S1000DBIKE-AAA-DA30000-0-U8025-00534-A-04-1Fig 1 Welded frame joints


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Subsequent frames (refer to Fig 2) can be made out of a wide variety of materials, includingaluminium, titanium, or chrome moly.

ICN-S1000DBIKE-AAA-DA30000-0-U8025-00503-A-04-1Fig 2 Frame

are different and can also be of different materials (for example, titanium or chrome moly). Somebicycle frames are of carbon fiber. To get this material, it is necessary to put sheets of carbon fibercloth on foam forms and epoxy them in position. This procedure gives a very light, strong structurethat can have different shapes.

The frame includes the parts that follow:

– the top tube (the higher bar of the bicycle frame)– the down tube (the section of the frame that extends from the stem to the bottom bracket)– the head tube (the part of the frame that the fork steerer tube goes through)– the seat tube (the vertical part of the frame that is the rear of the front triangle and that is

between the bottom bracket and the top tube)– the seat stay (the tube that includes the distance between the seat tube and the rear

dropouts)– the chain stay (the tube that is the bottom part of the rear triangle)

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Drivetrain


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Drive train..................................................................................................................................... 1


References


None

Table 1 References

Description

1 Drive trainThe drive train is the group of components that are necessary for the operation of the bicycle. Thedrive train is the primary system for the movement of the bicycle. A typical drive train has the chainwheels, the chain, the pedals and the saddle.

Since the drive train has many components, it is necessary to do a regular maintenance. The drivetrain maintenance is easy and the users can disassemble and assemble each part of the drivetrain. Because of this, when one part is defective, it is possible to remove and replace it with a newone.

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Gears


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Gears.............................................................................................................................................1


References


S1000DBIKE-AAA-DA5-10-00-00AA-041A-A Mechs — Description of how it is madeS1000DBIKE-AAA-DA5-30-00-00AA-041A-A Shifters — Description of how it is made

Table 1 References

Description

1 GearsThe gears include the mechanism, the hubs and the shifters.

The description of the mechanisms is given in S1000DBIKE-AAA-DA5-10-00-00AA-041A-A

The description of the shifters is given in S1000DBIKE-AAA-DA5-30-00-00AA-041A-A

The bicycles of these days can have 27 gears or more. The mountain bikes use a set that includes:

– Three socket sprockets of different dimension on the front– Nine socket sprockets of different dimensions at the rear

This set gives the gear ratios.

The shifters installed on the handlebars change the gears and operate the mechanisms (alsoknown as derailleurs). These derailleurs are cable-actuated mechanisms. They move the chainfrom the different sprockets.

The hub is the center of the wheel and contains the axle and bearings.

The gears let the rider crank at the pedals at a constant movement on slopes of different angles.

End of data module


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Mechs


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Derailleur.......................................................................................................................................11.1 Front derailleur.............................................................................................................................11.2 Rear derailleur..............................................................................................................................3


List of figuresFig 1 Front derailleur.............................................................................................................................2Fig 2 Rear derailleur..............................................................................................................................4

References


None

Table 1 References

Description

1 DerailleurThere are two different types of derailleur, the front and the rear.

1.1 Front derailleurThe front derailleur (refer to Fig 1) contains two types of screws to keep the movement of thederailleur to a minimum. These screws are:

the stop screw low-gearthe stop screw high-gear

The function of these screws is to prevent the rider from over shifting . If this occurs, the chain willgo out of the chain wheel.


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ICN-S1000DBIKE-AAA-DA51000-0-U8025-00519-A-04-1Fig 1 Front derailleur


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The derailleur is installed on the bicycle seat tube with a clamp and is parallel to the three frontsprockets.

The shift cable is connected between the shifters on the handle bars and the cable clamp bolt onthe front derailleur. This operates the derailleur. On the sprockets there is an inner and outer cage.The clamp attaches the cage.

1.2 Rear derailleurThe rear derailleur (refer to Fig 2) section contains the sprockets for the different gear changes.When the cable clamp bolt is tight, it holds the shift cable in its position. A screwed bolt holds thetension wheel.


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ICN-S1000DBIKE-AAA-DA51000-0-U8025-00520-A-04-1Fig 2 Rear derailleur


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The derailleur mounting bolt connects the derailleur to the frame. When the user attaches this bolt,this makes sure that the cage plates are parallel with the chain rings.

The guide wheel has the function to move the chain with the derailleur. It moves the chain from onesprocket to the other. The guide wheel must not move on its axis. If this occurs, there will be wearon the wheel. The position of the guide wheel is below the largest sprocket.

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Shifters


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Shifters.......................................................................................................................................... 12 How a thumb shifter is made up...............................................................................................3


List of figuresFig 1 Thumb shifter index type............................................................................................................2Fig 2 Unscrew wingnut......................................................................................................................... 4Fig 3 Loosen the nut............................................................................................................................. 5Fig 4 Loosen the shifter clamp bolt.................................................................................................... 7

References


None

Table 1 References

Description

1 ShiftersThe thumb shifter is a usual type in modern bicycles. It is possible to adjust this type of shifter foroperation in the index position or in the friction position. The differences between the two are:

– The index shifters change the gears with a click of a lever.– The friction shifters hold the derailleur in its position by friction.

The thumb shifters (refer to Fig 1) are held on the bicycle with a screw. The paragraph that followsgives a description of a thumb shifter.


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ICN-S1000DBIKE-AAA-DA53000-0-U8025-00535-A-04-1Fig 1 Thumb shifter index type


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2 How a thumb shifter is made upA wing nut (refer to Fig 2) from the top of the lever holds the thumb shifter. The lever is on top ofthe mount and the mount is on the handle bar with a nut. To remove the mount, it is necessary toloosen the nut of two turns (refer to Fig 3), then the mount can move from the handle bar from thetop of the lever. The lever sits on top of the mount and the mount is fixed into pace on the handlebar by a nut.


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ICN-S1000DBIKE-AAA-DA53000-0-U8025-00525-A-04-1Fig 2 Unscrew wingnut


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ICN-S1000DBIKE-AAA-DA53000-0-U8025-00526-A-04-1Fig 3 Loosen the nut


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On modern models of this shifter, there is a clamp bolt that holds the shifter in its position (refer toFig 4). The user can loosen the clamp bolt with an applicable tool. This lets the shifter release thehandlebar.


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ICN-S1000DBIKE-AAA-DA53000-0-U8025-00527-A-04-1Fig 4 Loosen the shifter clamp bolt

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Bicycle

Pre-operation procedures (crew)

Table of contents PagePre-operation procedures (crew).............................................................................................................. 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................6

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Required persons........................................................................................................................ 2Table 4 Support equipment......................................................................................................................2Table 5 Consumables, materials and expendables.............................................................................. 2Table 6 Spares...........................................................................................................................................2Table 7 Required conditions.................................................................................................................... 6

List of figuresFig 1 Hydraulic brake function.............................................................................................................3Fig 2 Brake pad seating....................................................................................................................... 4

References


S1000DBIKE-AAA-DA4-10-00-00AA-251B-A Chain — Clean with chain cleaning fluid

Table 1 References


Required conditions


None



S1000DBIKE-AAA-D00-00-00-00AA-121A-A




Required persons




Support equipment



1 EA


1 EA






Spares


None

Table 6 Spares


Procedure1 Examine the condition of the brakes.

1.1 Open the brake quick release.

1.2 Examine the condition and the thickness of the brake pads.



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1.2.1 Make sure that there is a large quantity of rubber left.

1.2.2 Make sure that the pad is not too hard.

1.3 Clean all the unwanted material.

2 Do an inspection of the installation of the brakes.

2.1 Check the hydraulic brake system function.

ICN-S1000DBIKE-AAA-DA10000-0-U8025-00537-A-03-1Fig 1 Hydraulic brake function

2.2 Make sure that there is sufficient clearance between the pad and the inner diameter of the brakesurface.

2.3

CAUTIONIf the position of the pads is too low on the rim, as shown inFig 2 , the pads can move. This could cause the separation

of the spokes from their mountings., they could slip offcausing the spokes to be torn out of their mountings.


S1000DBIKE-AAA-D00-00-00-00AA-121A-A




ICN-S1000DBIKE-AAA-DA10000-0-U8025-00515-A-04-1Fig 2 Brake pad seating



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Make sure that the pads are correctly installed in the center of the inner diameter of the brakesurface.

3 Do a check of the tire pressure.

3.1 Do a check of the tire pressure with the Tire pressure gauge .

3.2 Compare the value you read with the recommended pressure that is shown into the sidewall of thetire.

3.3 Add the necessary air.

4 Examine the condition of the wheels.

4.1 Examine the rims for bulges and dents.

4.2 Examine for splits at the seam where an extruded rim is bonded.

5 Do a check of the headset bearings.

5.1 Straddle the bicycle.

Apply the front brakes and push the handle bars forward.

5.2 Make sure that the headset bearings are tight.

6 Do the checks on the chain.

6.1 Visually examine the chain.

If the chain is too dirty, clean it as specified in the clean chain task (refer to S1000DBIKE-AAA-DA4-10-00-00AA-251B-A ).

6.1.1 Visually examine the chain for links that are frozen or that do not move easily.

6.1.2 Apply the necessary General lubricant .

6.2 Do a check of the chain to make sure that it is tight.

6.2.1 Make sure that the play of the chain is not too much.

6.2.1.1 Move the chain on the largest chain ring.


S1000DBIKE-AAA-D00-00-00-00AA-121A-A




6.2.1.2 Try to pull the chain away from the front of the chain ring.

Make sure that the chain is not loose. Tighten the chain if, when you pull it away from the chainring, you can see a full tooth.

6.2.2 Tighten the chain with the Allen wrench from the Specialist toolset.

Requirements after job completion

Required conditions


None


End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-130A-AApplicable to:


Bicycle

Riding a bicycle

Process

Variable declarations1 Variable

Name: ........................................................................nameType: ......................................................................... String

2 VariableName: ........................................................................ageType: ......................................................................... Integer

3 VariableName: ........................................................................levelType: ......................................................................... StringInitialize: "amateur"

4 VariableName: ........................................................................tourCorrectAnswerType: ......................................................................... BooleanInitialize: False

5 VariableName: ........................................................................tourMistakesType: ......................................................................... Integer

6 VariableName: ........................................................................approvedBikersType: ......................................................................... String set

Variable presets$age = "13"

Data module sequencedmSeq

dmNodeStep: Prerequisities

Please make sure you are familiar with the functional description of a bicycle: S1000DBIKE-AAA-D00-00-00-00AA-042A-A


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-130A-A


Applicable to:

dmNodedialog

dialogGroupdialogGroup

userEntryprompt

paraBasic Enter your name$name = userEntry dataEntryFieldLength="3"

promptparaBasic Enter your age

$age = validate errorMessage="Age must be within 4 to 100"($age >= 4) && ($age <= 100)

menu choiceSelection="single" choiceType="select"prompt

paraBasic Did you ever ride a bicycle?menuChoice

promptparaBasic Yes

$level = "experienced"menuChoice

promptparaBasic No

noAssertionsdialogGroup dialogSeparator="1"

messageprompt

paraBasic Age must be within 4 to 100prompt

paraBasic All fields are mandatorydmIfnot($level == "experienced")

dmThenSeqdmLoop$tourMistakes = 0tourFinished = False

dmNodeStep: Introduction

Dear $name, because you are an unexperienced user, you will be presented a briefintroduction on how to operate a bicycle.

Step: Click next.

dmNode S1000DBIKE-AAA-D00-00-00-00AA-043A-AdmNodeStep: Did you really read the instructions?

Before you can proceed to the practical section of this manual, you will be given asimple question to test whether you read the instructions carefully.

dmNodedialog

menu choiceSelection="single" choiceType="select"


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S1000DBIKE-AAA-D00-00-00-00AA-130A-AApplicable to:


promptparaBasic The rear brake is operated by

menuChoiceprompt

paraBasic Left brake lever$tourCorrectAnswer = False$tourMistakes = $tourMistakes + 1menuChoice

promptparaBasic Right brake lever

$tourCorrectAnswer = TruetourFinished [condition] = True

dmSeqAlts altsName="Rear brake lever answer"Applicable to: Inexperienced rider has the wrong answer.

dmNodeStep: Wrong answer!

You will be given the introduction once again.

Number of mistakes: $tourMistakes

Applicable to: Inexperienced rider has the right answer.dmNodeStep: Correct!

You can now continue with the practical part of this manual.

Applicable to:dmNodeStep: Practical part

Take the bicycle from the garage.

Step: Clean the bicycle from the dust.

Step: Sit on the bike.

Step: ...and RIDE!

Variable postsets$approved Bikers = $approved Bikers.Add($name)

End of data module



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Bicycle

Normal operation procedures (crew)

Table of contents PageNormal operation procedures (crew)........................................................................................................1References................................................................................................................................................... 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Correlation of tire pressure and terrain.................................................................................... 2

References


None

Table 1 References

Pre-ride inspectionBrakes

Pads1 Pads......................................................................... Free of unwanted material

2 Pads......................................................................... Acceptable pad width

3 Pads......................................................................... Acceptable pad clearance

Callipers1 Link Wire................................................................. Firmly attached

Levers1 Levers...................................................................... Approximately 1 inch of travel before

engagement

2 Levers...................................................................... Space between lever and handlebar whenfully pulled

Cables1 Cables...................................................................... No cuts or fraying


S1000DBIKE-AAA-D00-00-00-00AA-131A-A




Tires1 Pressure...................................................................

TirePressures Min Max

Off Road 35lbs 40lbsOn Road 55lbs 60lbs

Table 2 Correlation oftire pressure and terrain

2 Tires......................................................................... No cracks or splits

Wheels1 Wheels..................................................................... No loose bearings

2 Wheels..................................................................... True

3 Spokes..................................................................... Not broken

If: Spokes not broken4 Spokes............................................................. Tight

5 Axel Nuts................................................................. Tight

Headset1 Headset bearings................................................... Tight

Chain1 Links.........................................................................Easy movement of links

Handlebar

WARNINGDo not ride with a cracked stem

If: Stem cracked1 Procedure

Replace stem

Else if: Stem is loose1 Procedure

Tighten stem

If: Handlebars twist in stem2 Procedure

Tighten clamp bolt



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Computer1 Computer Display...................................................Applicable to: Mountain storm Mk1

ALTITUDE 0 miles

SPEED 0 mph

DISTANCE 0 miles

Applicable to: Brook trekker Mk9

SPEED 0 mph

DISTANCE 0 miles

End of data module



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Bicycle

Post-operation procedures (crew)

Table of contents PagePost-operation procedures (crew).............................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Support equipment......................................................................................................................1Table 4 Consumables, materials and expendables.............................................................................. 2Table 5 Spares...........................................................................................................................................2Table 6 Required conditions.................................................................................................................... 3

References


None

Table 1 References


Required conditions


None


Support equipment



1 EA



S1000DBIKE-AAA-D00-00-00-00AA-151A-A








Spares


None

Table 5 Spares


Procedure1 Clean the bicycle.

1.1 Clean the bicycle with water.

1.2 Use the brush from the Specialist toolset to clean the brakes, the shift levers, the sprockets andthe tires.

1.3 Let the bicycle dry.

2 Lubricate the bicycle

2.1 Spray the General lubricant, to these moving parts:

the brake pivotsthe derailleur pivotsthe derailleur tension guidesthe brake lever pivotsthe control cablesthe gear sprocketsthe chain

2.2 Remove the lubricant which is more than the necessary.



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Required conditions


None


End of data module


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Bicycle

Other procedures to clean

Table of contents PageOther procedures to clean......................................................................................................................... 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 4Requirements after job completion...........................................................................................................7

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Required persons........................................................................................................................ 2Table 4 Required persons........................................................................................................................ 2Table 5 Support equipment......................................................................................................................2Table 6 Consumables, materials and expendables.............................................................................. 2Table 7 Spares...........................................................................................................................................3Table 8 Required conditions.................................................................................................................... 7

List of figuresFig 1 Cleaning the bike.........................................................................................................................5Fig 2 Degreasing the freehub.............................................................................................................. 6

References


S1000DBIKE-AAA-DA4-10-00-00AA-241A-A Chain — Oil

Table 1 References


Required conditions


The bicycle is outdoors



MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258A-A




Applicable to: Mountain bicycle Brook trekker Mk9Required persons


Man A Chemical technician Intermediate Bike cleaner 1,0 h


Applicable to: Mountain bicycle Mountain storm Mk1Required persons


Man B Operator Intermediate Bike rider 1,0 h


Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Support equipment


Water hose Part: KZ666/PN BSK-TLST-001-09

1 EA


1 EA

Sponge Part: KZ666/PN BSK-TLST-001-11

1 EA




Degreasing agent Part: KZ222/PN LL-004 1 LDetergent A Part: KZ666/PN BSK-

TLST-023-141 L

Applicable to: Mountain bicycle Brook trekker Mk9Detergent B Part: KZ666/PN BSK-

TLST-001-151 L



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Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Spares


None

Table 7 Spares

Safety conditions

WARNINGDo not get Detergent A into your eyes. If it gets into

your eyes, wash them immediately in clean warm water.

WARNINGDo not get Detergent B into your eyes. If it gets into


CAUTIONDo not use a Water hose that has high pressure. A water hose that hashigh pressure can cause some parts to become loose or full of water.

CAUTIONDo not point the hose directly at the hub or at the bottom

bracket bearings. This can cause damage to the parts.


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258A-A




CAUTIONApply Detergent B in accordance with the instruction on the container. Thesubstance may cause damage to the Bike paint if it is not applied correctly.

Procedure1 Clean the bicycle with water to remove all dirt. Refer to Fig 1.


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ICN-S1000DBIKE-AAA-D000000-0-U8025-00502-A-04-1Fig 1 Cleaning the bike

2 Use a Stiff bristle brush to get access to areas that are not easy to clean. These are the shiftlevers, the knobbly tires, and the brakes.

3 Clean the caked grime from the chain and the sprockets with a screwdriver that has a small blade.

4 Remove the grease from the freewheel assembly with the Degreasing agent as shown in Fig 2 .Use a brush to remove the grease from these parts:

– sprockets– guide and tension wheels of the derailleur– chain ring teeth


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258A-A




ICN-S1000DBIKE-AAA-DA52000-0-U8025-00523-A-04-1Fig 2 Degreasing the freehub


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5 Flush the sprockets, the derailleurs, the chain rings and the chain with water.

Note 1If necessary, do the flush procedure again.

Applicable to: Mountain bicycle Mountain storm Mk16 Wash the Bike6.1 Soak the Sponge into Detergent A and water.

6.2 Clean the bicycle with the soaked sponge.

6.3 Flush the bicycle and make sure that all Detergent A is removed.

6.4 Move the bicycle up and down on its tires to remove all water.

Applicable to: Mountain bicycle Brook trekker Mk97 Wash the Bike7.1 Soak the Sponge into Detergent B and water.


7.3 Soak the Sponge into Detergent A and water.

7.4 Fully clean the bicycle with the soaked sponge.

7.5 Flush the bicycle to make sure that all detergents are removed.


Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)8 Lubricate the bicycle (refer to S1000DBIKE-AAA-DA4-10-00-00AA-241A-A).


Required conditions


Make sure the bicycle is dry


End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-258B-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Bicycle

Other procedures to clean

Table of contents PageOther procedures to clean......................................................................................................................... 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 4Requirements after job completion...........................................................................................................8

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Required persons........................................................................................................................ 2Table 4 Required persons........................................................................................................................ 2Table 5 Support equipment......................................................................................................................2Table 6 Consumables, materials and expendables.............................................................................. 2Table 7 Spares...........................................................................................................................................3Table 8 Required conditions.................................................................................................................... 8

List of figuresFig 1 Cleaning the bike.........................................................................................................................5Fig 2 Degreasing the freehub.............................................................................................................. 6

References


S1000DBIKE-AAA-DA4-10-00-00AA-241A-A Chain — Oil

Table 1 References


Required conditions


The bicycle is outdoors



MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258B-A




Applicable to: Mountain bicycle Brook trekker Mk9Required persons


Man A Chemical technician Intermediate Bike cleaner 1,0 h


Applicable to: Mountain bicycle Mountain storm Mk1Required persons


Man B Operator Intermediate Bike rider 1,0 h


Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Support equipment


Water hose Part: KZ666/PN BSK-TLST-001-09

1 EA


1 EA

Sponge Part: KZ666/PN BSK-TLST-001-11

1 EA




Degreasing agent Part: KZ222/PN LL-004 1 LDetergent A Part: KZ666/PN BSK-

TLST-023-141 L

Applicable to: Mountain bicycle Brook trekker Mk9Detergent B Part: KZ666/PN BSK-

TLST-001-151 L



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Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Spares


None

Table 7 Spares

Safety conditions

WARNINGDo not get Detergent A into your eyes. If it gets into


WARNINGDo not get Detergent B into your eyes. If it gets into


CAUTIONDo not use a Water hose that has high pressure. A water hose that hashigh pressure can cause some parts to become loose or full of water.

CAUTIONDo not point the hose directly at the hub or at the bottom

bracket bearings. This can cause damage to the parts.


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258B-A




CAUTIONApply Detergent B in accordance with the instruction on the container. Thesubstance may cause damage to the Bike paint if it is not applied correctly.

Procedure1 Clean the bicycle with water to remove all dirt. Refer to Fig 1.


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ICN-S1000DBIKE-AAA-D000000-0-U8025-00502-A-04-1Fig 1 Cleaning the bike

2 Use a Stiff bristle brush to get access to areas that are not easy to clean. These are the shiftlevers, the knobbly tires, and the brakes.

3 Clean the caked grime from the chain and the sprockets with a screwdriver that has a small blade.

4 Remove the grease from the freewheel assembly with the Degreasing agent as shown in Fig 2 .Use a brush to remove the grease from these parts:

– sprockets– guide and tension wheels of the derailleur– chain ring teeth


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258B-A




ICN-S1000DBIKE-AAA-DA52000-0-U8025-00523-A-04-1Fig 2 Degreasing the freehub


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5 Flush the sprockets, the derailleurs, the chain rings and the chain with water.

Note 1If necessary, do the flush procedure again.

Applicable to: Mountain bicycle Mountain storm Mk16 Wash the Bike



6.3 Flush the bicycle and make sure that all Detergent A is removed.


Applicable to: Mountain bicycle Brook trekker Mk96 Wash the Bike

6.1 Soak the Sponge into Detergent B and water.



6.4 Fully clean the bicycle with the soaked sponge.

6.5 Flush the bicycle to make sure that all detergents are removed.


Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)7 Lubricate the bicycle (refer to S1000DBIKE-AAA-DA4-10-00-00AA-241A-A).


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-00AA-258B-A





Required conditions


Make sure the bicycle is dry


End of data module


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Tire

Fill with air

Table of contents PageFill with air.................................................................................................................................................... 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


Man A Basic user Operator


Support equipment



1 EA

Foot pump Part: KZ666/PN BSK-TLST-001-05

1 EA


1 EA




None


Spares


None

Table 6 Spares


Procedure1 Ensure bicycle is on the repair stand.

2 Locate the deflated tire.


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3 Attach the outlet valve of the Foot pump, from the Specialist toolset, to the valve of the deflatedtire.

4 Inflate the tire.

4.1 Operate the foot pump to pump air into the tire.

4.2 Check tire pressure. Refer to S1000DBIKE-AAA-DA0-10-20-00AA-362B-A


Required conditions


None


End of data module


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Brake pads

Clean with rubbing alcohol

Table of contents PageClean with rubbing alcohol.........................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References



Table 1 References


Required conditions


None



MY CAVEAT





Required persons




Support equipment


None






Spares


None

Table 6 Spares


Procedure1 Do a visual inspection of the brakes as given in the pre-ride checks (refer to S1000DBIKE-AAA-

D00-00-00-00AA-121A-A).

2 Clean the brake pads.

2.1 Find each of the brake pads.

2.2 Apply a thin layer of the Rubbing alcohol on each of the brake pads.


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2.3 Rub the surface until you have applied the Rubbing alcohol to the complete surface of the pad.

2.4 Remove the unwanted alcohol.


Required conditions


None


End of data module


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Chain

Oil

Table of contents PageOil.................................................................................................................................................................. 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 3Requirements after job completion...........................................................................................................9


List of figuresFig 1 Derailleur pivots........................................................................................................................... 4Fig 2 Derailleur tension.........................................................................................................................5Fig 3 Brake lever pivots........................................................................................................................6Fig 4 Lubricate the chain......................................................................................................................8

References


None

Table 1 References


Required conditions


The bicycle chain is clean and dry



MY CAVEAT





Required persons


Man A Operator Intermediate Bike rider 0,5 h


Support equipment


Clean dry cloth Part: KZ666/PN BSK-TLST-001-12

1 EA

Floor covering Part: KK999/PN PPP-001 1 pack




Wet lube Part: KZ222/PN LL-007 1 dlDry lube Part: KZ222/PN LL-006 1 dl


Spares


None

Table 6 Spares

Safety conditions

WARNINGDry Lube is a very dangerous substance. Do not get it onto your skin. Use it

in a well ventilated area. If you swallow it seek immediate medical advice. If itgets into your eyes wash your eyes in clean water and seek medical advice.


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WARNINGWet Lube is a very dangerous substance. Do not get it onto your skin. Use itin a well ventilated area. If you swallow it seek immediate medical advice. If itgets into your eyes wash your eyes in clean water and seek medical advice.

Procedure1 Apply the penetrating lubricant into all the parts of the bike that move. This includes:

– derailleur pivots (refer to Fig 1)– derailleur tension (refer to Fig 2)– brake lever pivots (refer to Fig 3)

These brake lever pivots include:

– derailleur pivots– derailleur tension– guide wheels– brake lever pivots– control cables and where they go into their casings


MY CAVEAT





ICN-S1000DBIKE-AAA-DA51000-0-U8025-00521-A-04-1Fig 1 Derailleur pivots


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ICN-S1000DBIKE-AAA-DA51000-0-U8025-00522-A-04-1Fig 2 Derailleur tension


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00516-A-04-1Fig 3 Brake lever pivots


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2 Lubricate the chain.

2.1 Make sure the chain is clean and dry.

2.2 Put the Floor covering on the floor below the chain.

2.3 Use a Dry lube for dry conditions.

2.4 Use a Wet lube for wet conditions

2.5 Apply the lubricant to each roller of the chain (refer to Fig 4) but only apply a small quantity.


MY CAVEAT





ICN-S1000DBIKE-AAA-DA41000-0-U8025-00528-A-04-1Fig 4 Lubricate the chain


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2.6 Hold the nozzle of the container above the front of the chain ring and slowly turn the cranksrearwards.

2.7

CAUTIONDo not get lubrication oil into the brake system. Oil in the break

system can affect the efficiency of the bake system. Do not get oil ontothe floor where it can easily get transferred onto the brake system.

Let the lubricant soak into chain before you clean the unwanted lubricant from the chain.

3 Do a check of the rear wheel rim and clean the unwanted lubricant if necessary.

4 Do a check of the chain to make sure that each link is lubricated. If there are links that do not moveeasily or have become frozen, lubricate the chain again (refer to Step 2).

5 Do a check of the remaining lubricated parts and clean the unwanted lubricant with a Clean drycloth.


Required conditions


None


End of data module


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S1000DBIKE-AAA-DA4-10-00-00AA-251B-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Chain

Clean with chain cleaning fluid

Table of contents PageClean with chain cleaning fluid..................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References



Table 1 References


Required conditions


None


Support equipment



1 EA

Chain cleaning fluid Part: KZ222/PN LL-003 As required



MY CAVEAT






Chain cleaning tool Part: KZ666/PN BSK-TLST-001-03

1 EA

Table 3 Support equipment (Continued)



Floor covering Part: KK999/PN PPP-001 1 packGeneral lubricant Part: KZ222/PN LL-001 As required


Spares


None

Table 5 Spares


Procedure1 Inspect the chain.

Do the inspection of the chain as given in the pre-ride checks (refer to S1000DBIKE-AAA-D00-00-00-00AA-121A-A).

2 Prepare the cleaning area.

2.1 Put the Floor covering on a satisfactory floor area.

2.2 Put the bicycle on the floor covering.

3 Clean debris from the chain.

3.1 Use the Stiff bristle brush and loosen as much unwanted material as possible.


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3.2 Make sure that you remove all the unwanted material from the chain.

4 Clean the chain.

4.1 Open the Chain cleaning tool and fill with the Chain cleaning fluid.

4.2 Move the chain to the middle chainring and the middle sprocket at the rear.

4.3 Put the chain in the chain guides of the chain cleaning tool and lock the tool on the chain.

4.4 Hold the tool with the left hand and slowly turn the rearwards with the right hand.

4.5 Press the button on the cleaning tool to make sure that cleaning fluid flows until the tool is empty.

4.6 If necessary, remove the unwanted chain cleaning fluid.

5 Lubricate the chain.

5.1 Use the General lubricant and lubricate the chain.

5.2 Unlock and remove the cleaning tool.

5.3 If necessary, remove the unwanted lubricant.


Required conditions


Move the bicycle to its storage area and remove the floor covering.


End of data module


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S1000DBIKE-AAA-DA5-20-00-00AA-251C-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Hubs

Clean with degreasing agent

Table of contents PageClean with degreasing agent.....................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................5


List of figuresFig 1 Removing the axle.......................................................................................................................4

References


None

Table 1 References


Required conditions


Rear wheel removed S1000DBIKE-AAA-DA0-20-00-00AA-520A-A



MY CAVEAT





Required persons


Man B Supervisor Advanced Bicycle mechanic 0,8 hMan A Basic user Operator 0,3 h


Support equipment



1 EA




Degreasing agent Part: KZ222/PN LL-004 As requiredGeneral grease Part: KZ222/PN LL-005 As required


Spares


None

Table 6 Spares


Procedure1 Remove the axle.

1.1 Use the cone-wrench from the Specialist toolset and remove the locknut from one side of the axle.

1.2 Remove the washer and the cone from the axle.


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1.3

CAUTIONMake sure you do not lose the bearings from the hub. Be prepared to catchthe bearings if they fall out. Missing bearings can cause damage to the hub.

Pull the axle out from the other side as shown in Fig 1 .


MY CAVEAT





ICN-S1000DBIKE-AAA-DA52000-0-U8025-00524-A-04-1Fig 1 Removing the axle


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2 Remove the bearings.

2.1 Use a small screwdriver from the Specialist toolset and remove the bearings from their races.

2.2 Make sure that each side of the hub has the same number of bearings.

2.3 Use the Degreasing agent and clean all the parts of the hub.

2.4 Do a check of the axle to make sure that it is straight.

2.5 Examine the bearing contact area on the cones and the races in the hub for pitting and other signsof damage.

2.6 Do a check of the ball bearings for signs of damage.

2.7 Apply a large quantity of General grease on each hub race.

3 Assemble the hub.

3.1 Install the ball bearings into the races and push them into the grease.

3.2 Apply more grease on the tops of the bearings.

3.3 Install the axle through the hub.

3.4 Install the cone, the washer and the locknut on the other side of the axle.

3.5 Use the cone-wrench from the specialist toolset and carefully tighten the locknut.


Required conditions


None


End of data module



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Bicycle

Place on test stand

Table of contents PagePlace on test stand..................................................................................................................................... 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


None

Table 1 References


Required conditions


None



S1000DBIKE-AAA-D00-00-00-00AA-330A-A




Required persons




Support equipment


Test stand Part: KZ666/PN BSK-TLST-999-01

1 EA




None


Spares


None

Table 6 Spares


Procedure1 Ensure Test stand is level.

2 Place bicycle on the test stand.

3 Tight clamps until bicycle is securely attach to the test stand.



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Required conditions


None


End of data module


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Fork

Manual test

Table of contents PageManual test...................................................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


None

Table 1 References


Required conditions


None



MY CAVEAT

S1000DBIKE-AAA-D00-00-01-00AA-341A-A




Required persons




Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Climb on the bicycle.

2 Turn right and left several times.

3 Ride forward the bicycle.

4 Make sure that the wheels are stable.


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5 Push in the fork.

6 Make sure that no oil or air is leaking out the fork.


Required conditions


None


End of data module


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Tire

Check pressure

Table of contents PageCheck pressure............................................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


S1000DBIKE-AAA-DA0-10-10-00AA-921A-A Inner tube — Remove and install a new itemS1000DBIKE-AAA-DA0-10-20-00AA-215A-A Tire — Fill with air

Table 1 References


Required conditions


None



MY CAVEAT





Required persons




Support equipment



1 EA




None


Spares


None

Table 6 Spares


Procedure1 Locate the valve stem of tire.

2 Use the tire pressure gauge (Tire pressure gauge) to check the tire pressure.

3 Tire pressure should between 2000 hPa to 2700 hPa.

3.1 If tire pressure is less than 2000 hPa inflate tire. Refer to S1000DBIKE-AAA-DA0-10-20-00AA-215A-A


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3.2 If the tire cannot maintain pressure or the tire pressure is greater than 2700 hPa replace the innertube. Refer to S1000DBIKE-AAA-DA0-10-10-00AA-921A-A


Required conditions


None


End of data module


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Brake system

Manual test



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons




Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Put the bicycle in a vertical position.

2 Hold the handle bars and push the bicycle forwards.

3 Apply the brakes.

4 Make sure that the wheels lock and the bicycle stops.


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Required conditions


None


End of data module


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Front wheel

Fault reports and isolation procedures

Fault codesFault code Fault description

NYCJD04 Tire does not function correctly

Table of contents PageFault reports and isolation procedures.....................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................2Requirements after job completion...........................................................................................................3


References


S1000DBIKE-AAA-DA0-10-10-00AA-921A-A Inner tube — Remove and install a new itemS1000DBIKE-AAA-DA0-10-20-00AA-215A-A Tire — Fill with airS1000DBIKE-AAA-DA0-10-20-00AA-921A-A Tire — Remove and install a new item

Table 1 References

Fault isolation procedure

Fault codeNYCJD04

Fault descriptionTire does not function correctly


MY CAVEAT






Required conditions


None


Support equipment



1 EA


1 EA




None


Spares


None

Table 5 Spares


Isolation procedure1 Use the tire pressure gauge (Tire pressure gauge) to do a check of the pressure

What is the tire pressure reading?


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1.1 More than 2700 hPa: Go to Step 2.

1.2 Between 100 hPa and 2700 hPa: Go to Step 3.

1.3 Less than 100 hPa: Go to Step 4.

2 Deflate the tire until the pressure is 2700 hPa

Go to requirements after job completion

3 Inflate the tire as given in S1000DBIKE-AAA-DA0-10-20-00AA-215A-A


4 To do a check of the tire for damage

Is there damage to the tire?

4.1 Yes: Go to Step 5.

4.2 No: Go to Step 6.

5 Replace the tire (refer to S1000DBIKE-AAA-DA0-10-20-00AA-921A-A )


6 Replace the inner-tube (refer to S1000DBIKE-AAA-DA0-10-10-00AA-921A-A)



Required conditions


None


End of data module


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Rear wheel

Detected fault


NYCJD00 The rear wheel does not operate correctly

Table of contents PageDetected fault...............................................................................................................................................1References................................................................................................................................................... 1Fault reporting..............................................................................................................................................1


References


None

Table 1 References

Fault reporting

Fault codeNYCJD00

Fault descriptionThe rear wheel does not operate correctly

Fault detectionType: Major


MY CAVEAT





1 Detected LRULine replaceable unit

Nomenclature Identification

Tire Part: KT666/PN TIRES-010101

Isolate detected fault1 Fault isolation test – LRU

Line replaceable unit


Rear wheel Part: KZ333/PN WH-001

RemarksPrepare the rear wheel for the removal of the tire

End of data module


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Drive train

Correlated fault


Built-in test messages100FC01 The pedal mechanism is jammed200FC01 The derailleur is jammed

Table of contents PageCorrelated fault............................................................................................................................................ 1References................................................................................................................................................... 1Fault reporting..............................................................................................................................................1


References


None

Table 1 References

Fault reporting

Messages and warningsBuilt-in test messages1 Fault code: 100FC01

Fault descriptionThe pedal mechanism is jammed

2 Fault code: 200FC01Fault description

The derailleur is jammed


MY CAVEAT





Isolate detected fault1 Fault isolation test – LRU



Bicycle chain Part: KZ120/PN Tchain-120

RemarksPrepare the derailleur to put transmission chain back on pedal mechanism.

End of data module



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Bicycle

Standard repair procedures

Table of contents PageStandard repair procedures.......................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 3Requirements after job completion.........................................................................................................13

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Required persons........................................................................................................................ 2Table 4 Support equipment......................................................................................................................2Table 5 Consumables, materials and expendables.............................................................................. 2Table 6 Spares...........................................................................................................................................2Table 7 Required conditions.................................................................................................................. 13

List of figuresFig 1 Unseating the tire with a tire lever............................................................................................ 4Fig 2 Circle leak.....................................................................................................................................6Fig 3 Sanding the application area.....................................................................................................8Fig 4 Apply glue to application area.................................................................................................10Fig 5 Apply pressure to tube............................................................................................................. 12

References


S1000DBIKE-AAA-DA0-20-00-00AA-520A-A Rear wheel — Remove procedures

Table 1 References


Required conditions


None



S1000DBIKE-AAA-D00-00-00-00AA-663A-A




Required persons


Man A Operator Basic Bike rider 0,5 h


Support equipment


Tire lever Part: KZ666/PN BSK-TLST-001-04

1 EA

Foot pump Part: KZ666/PN BSK-TLST-001-05

1 EA

Marker pen Part: KZ666/PN BSK-TLST-001-07

1 EA

Tube patch kit Part: KZ666/PN BSK-TLST-001-07

1 EA




None


Spares


Inner-tube Part: KT222/PN IT-001 1 EA

Table 6 Spares



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Safety conditions

CAUTIONWhen you remove the rear wheel to repair a puncture,

disconnect the brake arm from the chain stay.

Procedure1 Remove the rear wheel. (Refer to S1000DBIKE-AAA-DA0-20-00-00AA-520A-A)

2 Make sure that there is no air in the tube.

2.1 Loosen the cap on the valve stem.

2.2 Push the valve stem core down to bleed all the air.

3 Use a Tire lever to move the tire bead out of its seat. Lift the tire bead above the lip of the rim.


S1000DBIKE-AAA-D00-00-00-00AA-663A-A




ICN-S1000DBIKE-AAA-DA00000-0-U8025-00506-A-04-1Fig 1 Unseating the tire with a tire lever



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4 Remove the tube.

5 Inflate (not fully) the tube with the Foot pump. Examine the tube for leaks.

6 If you find a leak, identify it with a circle made with a Marker pen.


S1000DBIKE-AAA-D00-00-00-00AA-663A-A




ICN-S1000DBIKE-AAA-DA01010-0-U8025-00508-A-04-1Fig 2 Circle leak



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7 Release most of the air.

8 Use a piece of sandpaper from the Tube patch kit and make the area on and around the holerough. This will help the patch bond correctly.


S1000DBIKE-AAA-D00-00-00-00AA-663A-A




ICN-S1000DBIKE-AAA-DA01010-0-U8025-00509-A-04-1Fig 3 Sanding the application area



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9 Apply a thin layer of glue from the patch kit on and around the hole. Make sure that the area withthe glue is larger than the patch.


S1000DBIKE-AAA-D00-00-00-00AA-663A-A




ICN-S1000DBIKE-AAA-DA01010-0-U8025-00510-A-04-1Fig 4 Apply glue to application area



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10 Let the glue dry for five minutes until it becomes tacky and dim.

11 Remove the rear foil from the patch (that is a part of the patch kit) and push the patch in itsposition.

12 Push with your thumbs from the center of the patch to the outer part of the applied area.


S1000DBIKE-AAA-D00-00-00-00AA-663A-A




ICN-S1000DBIKE-AAA-DA01010-0-U8025-00511-A-04-1Fig 5 Apply pressure to tube



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13 Remove the thin cover from the patch.

14 Put a very thin layer of talcum powder on and around the patch.

15 Inflate (not fully) the repaired tube with the foot pump.

16 Start at the valve stem and install the tube again between the tire and the rim.

17 Push the valve stem through the hole in the rim.

18 Make sure that the valve stem is straight.

19 Install the remaining of the tire.


Required conditions


None


End of data module


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Horn

Isolated fault


NYCJD03 Horn failed

Table of contents PageIsolated fault.................................................................................................................................................1References................................................................................................................................................... 1Fault reporting..............................................................................................................................................1


References


S1000DBIKE-AAA-DA3-10-00-00AA-921A-A Horn — Remove and install a new item

Table 1 References

Fault reporting

Fault codeNYCJD03

Fault descriptionHorn failed

Locate and repair1 Locate and repair LRU



Horn Part: KZ444/PN Horn-001


MY CAVEAT





Repair procedures: .............................................. S1000DBIKE-AAA-DA3-10-00-00AA-921A-A

End of data module


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Fork

Remove procedures

Table of contents PageRemove procedures....................................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 3Requirements after job completion...........................................................................................................3

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Required persons........................................................................................................................ 2Table 4 Required technical information.................................................................................................. 2Table 5 Support equipment......................................................................................................................2Table 6 Consumables, materials and expendables.............................................................................. 2Table 7 Spares...........................................................................................................................................2Table 8 Required conditions.................................................................................................................... 3

References


None

Table 1 References


Required conditions


None



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S1000DBIKE-AAA-D00-00-01-00AA-520A-A




Required persons


As required


Required technical information

Category Data module / Technical publication

Data module S1000DBIKE-AAA-DA2-10-00-00AA-520A-AData module S1000DBIKE-AAA-DA2-30-00-00AA-520A-A

Table 4 Required technical information

Support equipment


None




None


Spares


None

Table 7 Spares



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Procedure1 Remove the stem, refer to: S1000DBIKE-AAA-DA2-10-00-00AA-520A-A

2 Remove the headset, refer to: S1000DBIKE-AAA-DA2-30-00-00AA-520A-A

3 Push the fork downwards to remove it from the frame

4 Put the frame on the floor


Required conditions


None


End of data module


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S1000DBIKE-AAA-D00-00-01-00AA-720A-AApplicable to:Mountain bicycle and Mountainstorm Mk1


Fork

Install procedures

Table of contents PageInstall procedures........................................................................................................................................ 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 3Requirements after job completion...........................................................................................................3


References


None

Table 1 References


Required conditions


None



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S1000DBIKE-AAA-D00-00-01-00AA-720A-A


Applicable to:Mountain bicycle and Mountain

storm Mk1

Required persons


As required




Data module S1000DBIKE-AAA-DA2-10-00-00AA-720A-AData module S1000DBIKE-AAA-DA2-30-00-00AA-720A-AData module S1000DBIKE-AAA-DA2-40-00-00AA-720A-A


Support equipment


None






Spares


Fork set Part: KZ666/PNSPA-1000-1

1 EA Material set

– Fork Part: KZ666/PN FK-TEL1001

1 EA

Table 7 Spares


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S1000DBIKE-AAA-D00-00-01-00AA-720A-AApplicable to:Mountain bicycle and Mountainstorm Mk1



Procedure1 Apply grease (General grease) on the headset

2 Install the headset, refer to: S1000DBIKE-AAA-DA2-30-00-00AA-720A-A

3 To install the spacers, refer to: S1000DBIKE-AAA-DA2-40-00-00AA-720A-A

4 Install the stem, refer to: S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

5 Install the fork (Fork)


Required conditions


None


End of data module


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Fork

Replacement procedure

Table of contents PageReplacement procedure............................................................................................................................. 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 3Requirements after job completion...........................................................................................................4

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 2Table 3 Required technical information.................................................................................................. 2Table 4 Support equipment......................................................................................................................2Table 5 Consumables, materials and expendables.............................................................................. 3Table 6 Spares...........................................................................................................................................3Table 7 Required conditions.................................................................................................................... 4

References


None

Table 1 References

Preliminary requirementsApplicable to: Mountain bicycle and Mountain storm Mk1Production management data

Maintenance task durationPreliminary requirements 0 hProcedure 1,5 hRequirements after job completion 0 h

Applicable to: Mountain bicycle and Brook trekker Mk9Production management data

Maintenance task durationPreliminary requirements 0 hProcedure 1 hRequirements after job completion 0 h


MY CAVEAT

S1000DBIKE-AAA-D00-00-01-00AA-933A-A




Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Required conditions


None




Data module S1000DBIKE-AAA-DA0-30-00-00AA-520A-AData module S1000DBIKE-AAA-DA1-20-00-00AA-520A-AData module S1000DBIKE-AAA-D00-00-01-00AA-520A-AData module S1000DBIKE-AAA-D00-00-01-00AA-93AA-AData module Applicable to: Mountain bicycle and Mountain storm Mk1

S1000DBIKE-AAA-D00-00-01-00AA-720A-AApplicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Data module Applicable to: Mountain bicycle and Brook trekker Mk9

S1000DBIKE-AAA-D00-00-01-00AB-720A-AApplicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Data module S1000DBIKE-AAA-DA1-20-00-00AA-720A-AData module S1000DBIKE-AAA-DA0-30-00-00AA-720A-AData module S1000DBIKE-AAA-D00-00-01-00AA-341A-AData module BRAKE-AAA-DA1-00-00-00AA-341A-A


Support equipment


BSK-TLST-200 1 EA



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Spares

Name Identification/Reference Quantity RemarkApplicable to: Mountain bicycle and Mountain storm Mk1Fork set SPA-1000-1 1 EAApplicable to: Mountain bicycle and Brook trekker Mk9Fork FK-TEL1002 1 EA

Table 6 Spares

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Safety conditions

None

Procedure

1 PREPARATION1.1 Remove the front wheel, refer to: S1000DBIKE-AAA-DA0-30-00-00AA-520A-A

1.2 Remove the front brakes, refer to: S1000DBIKE-AAA-DA1-20-00-00AA-520A-A

2 PROCEDURE2.1 Remove the fork, refer to: S1000DBIKE-AAA-D00-00-01-00AA-520A-A

2.2 Change the bike axis, refer to: S1000DBIKE-AAA-D00-00-01-00AA-93AA-A

Applicable to: Mountain bicycle and Mountain storm Mk12.3 Install the new fork, refer to: S1000DBIKE-AAA-D00-00-01-00AA-720A-A

Applicable to: Mountain bicycle and Brook trekker Mk92.3 Install the new fork, refer to: S1000DBIKE-AAA-D00-00-01-00AB-720A-A


MY CAVEAT

S1000DBIKE-AAA-D00-00-01-00AA-933A-A




Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)2.4 Install the front brakes, refer to: S1000DBIKE-AAA-DA1-20-00-00AA-720A-A

2.5 Install the front wheel, refer to: S1000DBIKE-AAA-DA0-30-00-00AA-720A-A

3 TEST3.1 Test that the fork is properly installed, refer to: S1000DBIKE-AAA-D00-00-01-00AA-341A-A

3.2 Front brakes test, refer to: BRAKE-AAA-DA1-00-00-00AA-341A-A


Required conditions


None


End of data module


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S1000DBIKE-AAA-D00-00-01-00AA-93AA-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Bicycle axis

Modification procedures

Table of contents PageModification procedures............................................................................................................................. 1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


None

Table 1 References


Required conditions


None


Support equipment


Saw tool set BSK-TLST-200 1 EA Material set– Saw tool Part: KZ666/PN BSK-

TW-1001 EA



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S1000DBIKE-AAA-D00-00-01-00AA-93AA-A





– Threading tool Part: KZ666/PN BSK-THR-3001

1 EA

Table 3 Support equipment (Continued)



None


Spares


Wheel axis Part: KZ666/PN BSK-AXS-2001

1 EA Modified from

– Wheel axis Part: KZ666/PN BSK-AXS-2000

1 EA

Table 5 Spares


Procedure1 Use the (Saw tool) to saw the (Wheel axis)

Use the (Threading tool) when the saw is unbended

2 Put the frame on the floor


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S1000DBIKE-AAA-D00-00-01-00AA-93AA-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)



Required conditions


None


End of data module


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S1000DBIKE-AAA-D00-00-01-00AB-720A-AApplicable to:Mountain bicycle and Brooktrekker Mk9


Fork

Install procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT

S1000DBIKE-AAA-D00-00-01-00AB-720A-A


Applicable to:Mountain bicycle and Brook

trekker Mk9

Required persons


As required




Data module S1000DBIKE-AAA-DA2-10-00-00AA-720A-AData module S1000DBIKE-AAA-DA2-30-00-00AA-720A-A


Support equipment


None






Spares


Fork FK-TEL1002 1 EA

Table 7 Spares



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S1000DBIKE-AAA-D00-00-01-00AB-720A-AApplicable to:Mountain bicycle and Brooktrekker Mk9


Procedure1 Apply grease (General grease) on the headset

2 Install the headset, refer to: S1000DBIKE-AAA-DA2-30-00-00AA-720A-A

3 Install the stem, refer to: S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

4 Install the fork (Fork)


Required conditions


None


End of data module


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Inner tube

Remove and install a new item

Table of contents PageRemove and install a new item.................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................4


List of figuresFig 1 Removing the inner tube............................................................................................................ 3

References


S1000DBIKE-AAA-DA0-10-20-00AA-215A-A Tire — Fill with air

Table 1 References


Required conditions


The tire is removed. S1000DBIKE-AAA-DA0-10-20-00AA-215A-A



MY CAVEAT





Required persons




Support equipment


None




None


Spares


Inner tube Part: KT222/PN IT-001 1 EA

Table 6 Spares

Safety conditions

CAUTIONBe careful with sharp or hard tools. They can cause damage to the inner tube.

Procedure1 Remove the old inner-tube.


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ICN-S1000DBIKE-AAA-DA00000-0-U8025-00507-A-04-1Fig 1 Removing the inner tube

2 Install the new Inner tube.


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Required conditions


Replace the tire.Inflate the tire with air. S1000DBIKE-AAA-DA0-10-20-00AA-215A-A


End of data module


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Tire




References


S1000DBIKE-AAA-DA0-10-20-00AA-215A-A Tire — Fill with airS1000DBIKE-AAA-DA1-00-00-00AA-341A-A Brake system — Manual test

Table 1 References


Required conditions


None



MY CAVEAT





Required persons




Support equipment



1 EA

Tire lever Part: KZ666/PN BSK-TLST-001-04

1 EA

Tire pressure guage Part: KZ666/PN BSK-TLST-001-01

1 EA




None


Spares


Tire Part: KT666/PNTIRES-010101

1 EA

Table 6 Spares


Procedure1 Lift and turn the bicycle and make sure the bicycle is held safely in this position.

2 Use a standard wrench from the Specialist toolset and loosen the brake caliper.


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3 Remove the axle bolt.

4 Remove the wheel.

5 Deflate the tire.

6 Use the Tire lever from the Specialist toolset and remove the old tire from the wheel.

7 Use the Tire lever from the Specialist toolset and attach the new Tire to the wheel. Refer toS1000DBIKE-AAA-DA0-00-00-00AA-041A-A

8 Inflate the tire (refer to S1000DBIKE-AAA-DA0-10-20-00AA-215A-A).

9 Install the wheel.

10 Tighten the axle bolt.

11 Tighten the brake caliper.


Required conditions


Lift and turn the bicycle to the correct position.Do a test of the brakes as given in the brake testprocedure.



End of data module


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Rear wheel

Remove procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Hold the rear of the bicycle.

2 Push the wheel forwards and down to disengage the chain from the sprocket.

3 Turn the wheel to the side and lift it away from the frame.

4 Put the frame on the floor.


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Required conditions


None


End of data module


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Front wheel

Remove procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment



1 EA




None


Spares


None

Table 6 Spares


Procedure1 Hold the front of the bicycle.

2 Use the (Specialist toolset) to disengage the fork from the chainring by pushing the wheel forwardsand down.

3 Lift the wheel away from the frame.


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Required conditions


None


End of data module


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Front wheel

Install procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment



1 EA




None


Spares


None

Table 6 Spares


Procedure1 Note 1

It is necessary to install the fork and the brakes before installing the wheel

2 Hold the front of the bicycle.

3 Install the wheel with (Specialist toolset) and be careful to not damage the chainring.


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4 Put the bike on the floor.


Required conditions


None


End of data module


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Front brake

Remove procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Hold the front of the bicycle.

2 Remove the front brake forwards.



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Required conditions


None


End of data module


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Front brake

Install procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Note 1

It is necessary to install the fork before installing the brakes

2 Hold the front of the bicycle.

3 Install the front brakes on the fork.



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Required conditions


None


End of data module


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Stem

Remove procedures



List of figuresFig 1 Remove the bolt.......................................................................................................................... 3

References


S1000DBIKE-AAA-DA2-20-00-00AA-520A-A Handlebar — Remove procedures

Table 1 References


Required conditions


Safety the bicycle in a bicycle stand and hold the front wheel off the ground



MY CAVEAT





Required persons


Man A Bike Rider Intermediate Operator 1,5 h


Support equipment


Set of Allen wrenches Part: KZ666/PN BSK-TLST-001-13

1 EA

Work stand Part: KZ555/PNStand-001

1 EA




None


Spares


None

Table 6 Spares

Safety conditionsNote 1

It is not necessary to remove the handlebar when you remove the stem to get access to the headset.

Procedure1 Remove the handlebar S1000DBIKE-AAA-DA2-20-00-00AA-520A-A

2 Remove the stem.

2.1 Remove the bolt in the center of the stem cap.


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ICN-S1000DBIKE-AAA-DA21000-0-U8025-00531-A-04-1Fig 1 Remove the bolt


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2.2 Loosen the stem clam bolt with a Set of Allen wrenches.

2.3 Remove the stem from the steerer tube.

2.4 Note: It is not necessary to remove the handlebar if you remove the stem to get access to theheadset.


Required conditions


None


End of data module


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Stem

Install procedures



List of figuresFig 1 Lubricate the thread....................................................................................................................4Fig 2 Tighten the bolt............................................................................................................................6

References


S1000DBIKE-AAA-DA2-20-00-00AA-720A-A Handlebar — Install procedures

Table 1 References


Required conditions


Make sure the bicycle is held safely on a work stand with the front wheel free of the ground



MY CAVEAT





Required persons




Support equipment


Clean dry cloth Part: KZ666/PN BSK-TLST-001-12

1 EA


1 EA




Rubbing alcohol Part: KZ222/PN LL-002 1 LGeneral lubricant Part: KZ222/PN LL-001 1 L


Spares


Stem Part: KZ555/PN St-001 1 EAStem bolt Part: KZ555/PN St-001-01 1 EA

Table 6 Spares

Safety conditions

CAUTIONDo not tighten the stem bolt too much. You can cause damage

to the headset bearings if you tighten the stem too much.


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CAUTIONThe stem bolt does not safety the stem.

Note 1The stem must point forward in alignment with the wheel.

Procedure1 Remove all the rust and the corrosion with a Clean dry cloth and Rubbing alcohol.

2 Install the stem.

2.1 Use a General lubricant and lubricate:

– the threads of the Stem and Stem bolt– the sides– the top of the wedge


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ICN-S1000DBIKE-AAA-DA21000-0-U8025-00529-A-04-1Fig 1 Lubricate the thread


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2.2 Install the Stem in the steerer tube.


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ICN-S1000DBIKE-AAA-DA21000-0-U8025-00530-A-04-1Fig 2 Tighten the bolt


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2.3 Adjust to align the Stem with the wheel and tighten the Stem bolt firmly.

3 Install the handlebars (refer to S1000DBIKE-AAA-DA2-20-00-00AA-720A-A).


Required conditions


None


End of data module


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Handlebar

Remove procedures



List of figuresFig 1 Loosen the clamp screw with the Allen wrench...................................................................... 4Fig 2 Loosen the clamp bolt................................................................................................................ 6

References


None

Table 1 References


Required conditions


The bicycle is held safely on a work stand.



MY CAVEAT





Required persons


Man A Bike rider Intermediate Operator 1,5 h


Support equipment



1 EA


1 EA




None


Spares


None

Table 6 Spares

Safety conditions

WARNINGDo not ride a bicycle with no grips on the handlebar.

This can cause the hands of the rider to slip.


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Procedure

1 Remove the grips1.1 Put a long thin screwdriver below the grip and apply water between the grip and the handle bar.

1.2 Turn the grip forwards and rearwards to loosen it and then pull it off the end of the handlebar.

2 Remove the brake and the shift levers from the handlebars2.1 Loosen the clamp screw (refer to Fig 1 ) which is behind or below the brake lever (as shown).


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ICN-S1000DBIKE-AAA-DA22000-0-U8025-00518-A-04-1Fig 1 Loosen the clamp screw with the Allen wrench


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2.2 Remove the lever and the mount from the handlebar.

2.3 Loosen the clamp bolt and remove the shifter from the handlebar.

3 Remove the handlebarUse a Set of Allen wrenches and loosen the clamp bolt (refer to Fig 2 ). To remove, move thehandlebar out of the stem.


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ICN-S1000DBIKE-AAA-DA22000-0-U8025-00517-A-04-1Fig 2 Loosen the clamp bolt


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Required conditions


None


End of data module


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Handlebar

Install procedures



References


None

Table 1 References


Required conditions


The bicycle is held safely on work stand. Refer to (Work stand)



MY CAVEAT





Required persons


Man A Bike rider Intermediate Operator 1,5 h


Support equipment



1 EA

Extra firm hold hairspray Part: HS111/PN HSP-D001

1 EA


1 EA




None


Spares


Handlebar Part: KZ555/PN Hd-001 1 EABrake lever Part: KT444/PN BR-

LVRS-0011 EA

Shifter lever Part: KZ555/PN Sl-001 1 EABrake lever mount Part: KT444/PN BR-

LVRS-001-011 EA

Handlebar grips Part: KZ555/PNHd-001-01

1 EA

Handlebar plug Part: KZ555/PNHd-001-02

1 EA

Table 6 Spares


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Safety conditions

WARNINGDo not ride the bicycle until the grips have become dry and are firmly held in position.

If the grips are wet, your hands can move off the grips when you ride the bicycle.

WARNINGDo not ride a bicycle with no grips on the handlebar.

CAUTIONMake sure the handlebar is correctly aligned in the center of the stem.

Procedure1 Put the Handlebar in the stem and tighten the clamp bolt with a Set of Allen wrenches. Make sure

the handlebar is correctly aligned in the center of the stem. Tighten the clamp bolt.

2 Put the Brake lever and Shifter lever on the handlebar.

2.1 Move the Shifter lever on the Handlebar again and make sure you do not catch the cables.

2.2 Tighten the clamp bolt.

2.3 Move the Brake lever mount and the brake lever on the Handlebar again.

2.4 Tighten the clamp screw.

3 Replace the Handlebar grips.

3.1 Apply with the Extra firm hold hairspray to the Handlebar grips area of the Brake lever mount.


MY CAVEAT





3.2 Before the Extra firm hold hairspray becomes dry, move the Handlebar grips into the correctposition. Make sure the grip protects the end of the Handlebar or install a Handlebar plug.


Required conditions


None


End of data module


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Headset

Remove procedures



List of figuresFig 1 Lift the upper bearing cup..........................................................................................................4

References


S1000DBIKE-AAA-DA2-10-00-00AA-520A-A Stem — Remove procedures

Table 1 References


Required conditions


The bicycle is safely held on a work stand



MY CAVEAT





Required persons




Support equipment


Work stand Part: Bikey/PN Stand-001 1 EA




None


Spares


None

Table 6 Spares

Safety conditionsNote 1

It is not necessary to remove the handlebar for this procedure.

Procedure1 Remove the stem (refer to S1000DBIKE-AAA-DA2-10-00-00AA-520A-A).

2 Remove:

the spacersthe brake cable hangarthe dust sealsthe conical expansion washer(s) from the steerer tube


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3 Lift the upper bearing cup off (refer to Fig 1) and then remove the fork from the frame.


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ICN-S1000DBIKE-AAA-DA23000-0-U8025-00532-A-04-1Fig 1 Lift the upper bearing cup


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Required conditions


None


End of data module


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Headset

Install procedures



References


S1000DBIKE-AAA-DA2-10-00-00AA-720A-A Stem — Install procedures

Table 1 References


Required conditions


The bicycle is safely held on a work stand



MY CAVEAT





Required persons




Support equipment


Work stand Part: Stand/PN Stand-001 1 EA




None


Spares


Frame fork Part: KZ555/PN St-001-02 1 EAUpper bearing cup Part: KZ555/PN St-001-03 1 EABrake cable hangar Part: KT444/PN BR-

LVRS-0021 EA

Dust seal Part: KZ555/PN St-001-04 1 EAConical expansion washer Part: KZ555/PN St-001-05 1 EA

Table 6 Spares


Procedure1 Install the Frame fork on the frame.

2 Install the Upper bearing cup.


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3 Install the components that follow on the steering tube:

the Brake cable hangarthe Dust sealthe Conical expansion washer

4 Install the stem (refer to S1000DBIKE-AAA-DA2-10-00-00AA-720A-A).


Required conditions


None


End of data module


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S1000DBIKE-AAA-DA2-40-00-00AA-720A-AApplicable to:Mountain bicycle and Mountainstorm Mk1


Spacer

Install procedures



References


None

Table 1 References


Required conditions


None



MY CAVEAT



Applicable to:Mountain bicycle and Mountain

storm Mk1

Required persons


As required


Support equipment


None




None


Spares


Fork set Part: KZ666/PNSPA-1000-1

1 EA Material set

– Spacer Part: KZ666/PNSPC-200-12

1 EA

Table 6 Spares


Procedure1 Note 1

It is necessary to install the headset before installing any spacer

2 Install the spacer (Spacer)


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S1000DBIKE-AAA-DA2-40-00-00AA-720A-AApplicable to:Mountain bicycle and Mountainstorm Mk1



Required conditions


None


End of data module


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Horn




References


Local Disposal Procedures

Table 1 References


Required conditions


None



MY CAVEAT





Required persons


As required


Support equipment



1 EA

8mm Allen wrench Part: KZ666/PN BSK-TLST-001-08

1 EA




None


Spares


Horn Part: KZ444/PN Horn-001 1 EA

Table 6 Spares


Procedure1 Safely hold the bicycle.

2 Remove the horn.

2.1 Use the 8mm Allen wrench from the Specialist toolset and remove the two Allen screws.


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2.2 Remove the horn.

3 Install the new Horn.

3.1 Install the new Horn on the handlebars.

3.2 Use the 8mm Allen wrench from the Specialist toolset and tighten the two Allen screws.


Required conditions


Safely discard the horn that you removed


End of data module


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S1000DBIKE-C3002-LOAP1-00

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Bicycle

Service Bulletin - Replacement ofstandard forward fork by telescopic fork

Table of contents PageService Bulletin - Replacement of standard forward fork by telescopic fork....................................... 1References................................................................................................................................................... 1Service bulletin............................................................................................................................................ 1Management information............................................................................................................................1Revision information....................................................................................................................................3Summary.......................................................................................................................................................4Planning information................................................................................................................................... 5Material information.....................................................................................................................................8Accomplishment instructions................................................................................................................... 11Additional information............................................................................................................................... 11

List of tablesTable 1 References....................................................................................................................................1Table 2 List of product modifications......................................................................................................1Table 3 List of impacts..............................................................................................................................2Table 4 Accomplishment limit.................................................................................................................. 2Table 5 Time assessment........................................................................................................................ 2Table 6 Service bulletin approved data modules.................................................................................. 2Table 7 List of generic properties............................................................................................................3Table 8 Accomplishment time scale....................................................................................................... 6

References


None

Table 1 References

Service bulletin

Management informationCompliance category: .........................................................OptionalTask type: ............................................................................Modification

Table 2 List of product modifications


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Ident Class Description Applicability

A2001 Major Mountain bicycle and Mountain stormMk1Installation of telescopic fork with140mm clearance

Mountain bicycle and Mountain stormMk1

A2002 Major Mountain bicycle and Brook trekkerMk9Installation of telescopic fork with100mm clearance

Mountain bicycle and Brook trekkerMk9

Table 2 List of product modifications (Continued)

No. Type Quantity Description ApplicabilityMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)1 Weight +0.8 kg +1.76 lbm Mountain bicycle and Mountain

storm Mk12 Weight +0.5 kg +1.1 lbm Mountain bicycle and Brook

trekker Mk9

Table 3 List of impacts

List of concurrent service bulletins: .................................. No Info

No. Time compliance References Applicability

1 Basic limitLimit:Perform once

Grace periodLimit:Perform once

Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)

Table 4 Accomplishment limit

Duration Estimatedtime

Condition References Applicability

1.5 h 1.5 h S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Mountain bicycle andMountain storm Mk1

1 h 1 h S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Mountain bicycle andBrook trekker Mk9

Table 5 Time assessment

Original issue date: .............................................................2011-03-31Service bulletin approval: .................................................. S1000D-020AA

Table 6 Service bulletin approved data modules


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S1000DBIKE-AAA-D00-00-01-00AA-933A-AS1000DBIKE-AAA-DA0-30-00-00AA-520A-AS1000DBIKE-AAA-DA1-20-00-00AA-520A-AS1000DBIKE-AAA-D00-00-01-00AA-520A-AS1000DBIKE-AAA-D00-00-01-00AA-93AA-AApplicable to: Mountain bicycle and Mountain storm Mk1S1000DBIKE-AAA-D00-00-01-00AA-720A-AS1000DBIKE-AAA-DA2-40-00-00AA-720A-AApplicable to: Mountain bicycle and Brook trekker Mk9S1000DBIKE-AAA-D00-00-01-00AB-720A-AApplicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)S1000DBIKE-AAA-DA1-20-00-00AA-720A-AS1000DBIKE-AAA-DA0-30-00-00AA-720A-AS1000DBIKE-AAA-D00-00-01-00AA-341A-A

Table 6 Service bulletin approved data modules (Continued)

Type Applicable Applicability

Passenger comfort affected Applicable: YesStructural life extension Applicable: YesProduct operation affected Applicable: Yes

Table 7 List of generic properties

Revision information

Revision historyThis document is the first issue of the Service Bulletin

Revision sequenceOriginal Issue date 2011-03-31


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S1000DBIKE-AAA-D00-00-01-00AA-930A-A




Summary

ReasonA lot of customers asked for the improvement of the front hanging in order to use the bike in moresevere conditions.

DescriptionReplacement of the fork

ComplianceCompliance: Optional

ApplicabilityThis Service Bulletin is applicable to bikes manufactured between 01/05/2001 and 30/09/2009

Applicable to: Mountain bicycle and Mountain storm Mk1Configuration no. 1 covers mountain bicycle Mountain storm version Mk1

Applicable to: Mountain bicycle and Brook trekker Mk9Configuration no. 2 covers mountain bicycle Brook trekker version Mk9

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Concurrent Requirements

No Info

ManpowerApplicable to: Mountain bicycle and Mountain storm Mk1

S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Total workload 1.5 h

Estimated time 1.5 h

Applicable to: Mountain bicycle and Brook trekker Mk9

S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Total workload 1 h

Estimated time 1 h


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Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Industry Support Information

For any issue with the fork assembly, please contact your local retailer.

The UK MoD Company only provides assistance via its network of retailers.

General evaluation

EVALUATION TABLE

Passengercomfort affected

Passenger comfort affected

Structural lifeextended

Structural life extension

Bike operationaffected

Product operation affected

Planning information

ApplicabilityThis Service Bulletin is applicable to bikes manufactured between 01/05/2001 and 30/09/2009

Applicable to: Mountain bicycle and Mountain storm Mk1The S/N of the impacted bikes are : Part: U8025/PN [SN 1B070701]

Applicable to: Mountain bicycle and Brook trekker Mk9The S/N of the impacted bikes are : Part: U8025/PN [SN 1B070643]Part: U8025/PN [SN1B070644]

Applicable to: Mountain bicycle and Mountain storm Mk1Configuration no. 1 covers mountain bicycle Mountain storm version Mk1

Applicable to: Mountain bicycle and Brook trekker Mk9Configuration no. 2 covers mountain bicycle Brook trekker version Mk9

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Concurrent Requirements

No Info

Reason1 Objective :


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S1000DBIKE-AAA-D00-00-01-00AA-930A-A




1.1 Improvement of the bike's front hanging.

2 Problem and effect :

2.1 A lot of customers would like to use the bike in more severe conditions.

3 Solution :

3.1 Replacement of the fork.

Description1 Replacement of the original fork

Applicable to: Mountain bicycle and Mountain storm Mk11.1 by telescopic fork with a 140 mm clearance

Applicable to: Mountain bicycle and Brook trekker Mk91.2 by telescopic fork with a 100 mm clearance

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Compliance1 Compliance

Compliance: Optional

2 The modification should be made in accordance with the customer's availability, but within thefollowing limits (before marked wear of the frame)

Limit Grace period

Basic limitLimit:Perform once

Grace periodLimit:Perform once

Table 8 Accomplishment time scale


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ApprovalThis modification has been approved and certified in conformity with the requirements of theS1000D community.

Approval No. S1000D-020AA.

ManpowerApplicable to: Mountain bicycle and Mountain storm Mk1

S1000DBIKE-AAA-D00-00-01-001A-933A-A

Job Set-up 5 min

Removal 20 min

Install 60 min

Testing 5 min

Total workload 1.5 h

Estimated time 1.5 h

Applicable to: Mountain bicycle and Brook trekker Mk9

S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Job Set-up 5 min

Removal 20 min

Install 30 min

Testing 5 min

Total workload 1 h

Estimated time 1 h

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Weight and Balance

Applicable to: Mountain bicycle and Mountain storm Mk1Effect on weight Impact 1Applicable to: Mountain bicycle and Brook trekker Mk9Effect on weight Impact 2


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Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Electrical Load Data

No Info

Software Accomplishment SummaryNo Info

Referenced DocumentationRemoval of the headset S1000DBIKE-AAA-DA2-30-00-00AA-520A-A

Install of the headset S1000DBIKE-AAA-DA2-30-00-00AA-720A-A

Removal of the stem S1000DBIKE-AAA-DA2-10-00-00AA-520A-A

Install of the stem S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

Testing of the brakes BRAKE-AAA-DA1-00-00-00AA-341A-A

Documentation AffectedIPD S1000DBIKE-AAA-D00-00-00-00AA-941A-D

Industry Support InformationFor any issue with the fork assembly, please contact your local retailer.

The UK MoD Company only provides assistance via its network of retailers.

Material information

List of material setsApplicable to: Mountain bicycle and Mountain storm Mk11 Material description:

Material set reference: ....................................Saw tool setQuantity: ........................................................... 1 EA

Material description:Material set reference: ....................................Supplies

Material description:Material set reference: ....................................Fork setQuantity: ........................................................... 1 EA

Material description:Material set reference: ....................................Removed spare set

Material description:Material set reference: ....................................Modified spare


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Applicable to: Mountain bicycle and Brook trekker Mk92 Material description:

Material set reference: ....................................Saw tool setQuantity: ........................................................... 1 EA

Material description:Material set reference: ....................................Supplies

Material description:Material set reference: ....................................ForkQuantity: ........................................................... 1 EA

Material description:Material set reference: ....................................Removed spare set

Material description:Material set reference: ....................................Modified spare

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)List of support equipment1 Support equipment set

Material ident: .......................................................... BSK-TLST-200Material type: ........................................................... Set of material or individual material specific to

the Service BulletinMaterial issue: ..........................................................001Material is procurable: ............................................ YesSupplier: ....................................................................ManufacturerName: ........................................................................Saw tool setIndividual support equipmentMaterial type: ........................................................... Set of material or individual material specific to

the Service BulletinEmbedded support equipment description: ..........Saw toolPart: KZ666/PN BSK-TW-1001 EAIndividual support equipmentMaterial type: ........................................................... Set of material or individual material specific to

the Service BulletinEmbedded support equipment description: ..........Threading toolPart: KZ666/PN BSK-THR-30011

EA

List of supplies1 Individual supply

Material type: ........................................................... Set of material or individual material not speciallybuilt for the Service Bulletin

Material is procurable: ............................................ YesSupplier: ....................................................................AnyEmbedded supply description: ...............................General greasePart: KZ222/PN LL-005As

required


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List of sparesApplicable to: Mountain bicycle and Mountain storm Mk11 Spare set

Material ident: .......................................................... SPA-1000-1Material type: ........................................................... Set of material or individual material specific to

the Service BulletinMaterial issue: ..........................................................001Material is procurable: ............................................ YesSupplier: ....................................................................ManufacturerName: ........................................................................Fork setProcurement data:

Price information: ............................................ 150 USDAvailability: ....................................................... 3 d

after purchase order receptionProcurement address: .................................... KZ666

Individual spareMaterial type: ........................................................... Set of material or individual material not specially

built for the Service BulletinEmbedded spare description: ................................ ForkPart: KZ666/PN FK-TEL10011 EAIndividual spareMaterial type: ........................................................... Set of material or individual material not specially

built for the Service BulletinEmbedded spare description: ................................ SpacerPart: KZ666/PN SPC-200-122 EA

Applicable to: Mountain bicycle and Brook trekker Mk92 Individual spare

Material ident: .......................................................... FK-TEL1002Material type: ........................................................... Set of material or individual material specific to

the Service BulletinMaterial issue: ..........................................................001Material is procurable: ............................................ YesSupplier: ....................................................................ManufacturerEmbedded spare description: ................................ ForkPart: KZ666/PN FK-TEL10021 EAProcurement data:

Price information: ............................................ 100 USDAvailability: ....................................................... 3 d

after purchase order receptionProcurement address: .................................... KZ666

Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)List of removed sparesApplicable to: Mountain bicycle and Mountain storm Mk11 Removed spare set

Name: ........................................................................Removed spare setIndividual removed spareRemoved spare description: .................................. Discarded

ForkPart: KZ666/PN FK-1000


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InterchangeabilityReplacement part

Replaced by (02): ........................................... Part: FK-TEL1001Individual removed spareRemoved spare description: .................................. Discarded

Conical expansion washerSt-001-05Applicable to: Mountain bicycle and Brook trekker Mk92 Removed spare set

Name: ........................................................................Removed spare setIndividual removed spareRemoved spare description: .................................. Discarded

ForkPart: KZ666/PN FK-1000InterchangeabilityReplacement part

Replaced by (02): ........................................... Part: FK-TEL1002Individual removed spareRemoved spare description: .................................. Discarded

Conical expansion washerSt-001-05Applicable to: Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)3 Individual removed spare

Material type: ........................................................... Set of re-identified materialRemoved spare description: .................................. Modified to

Wheel axisBSK-AXS-2000InterchangeabilityReplacement part

Altered to part: .................................................BSK-AXS-2001

Accomplishment instructions


S1000DBIKE-AAA-D00-00-01-00AA-933A-A

Table 8 Accomplishment instructions

Additional informationNo Info

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T10BApplicable to:


Bicycle

Servicing: Attention

Table of contents PageServicing: Attention..................................................................................................................................... 1References................................................................................................................................................... 1Learning overview....................................................................................................................................... 11 ....................................................................................................................................................... 11.1 Entry behavior.............................................................................................................................. 12 ....................................................................................................................................................... 13 Resources.....................................................................................................................................14 Section.......................................................................................................................................... 2


List of figuresFig 1 ....................................................................................................................................................... 2

References


None

Table 1 References

Learning overview

11.1 Entry behavior23 Resources


S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T10B


Applicable to:

4 Section

ICN-S1000DBIKE-AAA-D000000-A-06RT9-00149-A-001-01Fig 1

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T36DApplicable to:


Bicycle

Servicing: Prerequisite concept review

Table of contents PageServicing: Prerequisite concept review.................................................................................................... 1References................................................................................................................................................... 1Learning summary.......................................................................................................................................21 Next steps.....................................................................................................................................22 Resources.....................................................................................................................................23 Section.......................................................................................................................................... 2


List of figuresFig 1 Bike operation.............................................................................................................................. 2

References


None

Table 1 References




Applicable to:

Learning summary

Summary

ICN-S1000DBIKE-AAA-D000000-A-06RT9-00150-A-001-01Fig 1 Bike operation

Regular cleaning and testing of your bike's systems are part of keeping your bike maintained. Over time, yourbike's moving parts become susceptible to dirt and grime and will eventually fail to operate correctly if they arenot maintained. Because the bike has so many moving parts, it is important that you know how to keep the bikeclean and lubricated.

It is also important to know how to patch an inner tube puncture. As you are riding, you never know what youmight run over. A nail or a tack can cause quite a bit of aggravation.

1 Next steps2 Resources3 Section

Now that you have completed this topic, you should be able to perform some general maintenanceon your bike.

End of data module


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S1000DBIKE-AAA-D00-00-00-00AA-952A-T-H31AApplicable to:


Bicycle

Performance support

Table of contents PagePerformance support.................................................................................................................................. 1References................................................................................................................................................... 2Learning plan............................................................................................................................................... 21 Basic Bike Awareness................................................................................................................21.1 National Bike Courier Association (NBCA)..............................................................................21.2 Getting to Know Your Bike........................................................................................................ 21.3 Course Identification Number.................................................................................................... 21.4 Modification Date.........................................................................................................................31.5 Delivery Date................................................................................................................................31.6 Learning Plan Subject Matter....................................................................................................32 Performance Analysis................................................................................................................. 32.1 Organizational Analysis.............................................................................................................. 32.1.1 Vision statement.......................................................................................................................... 32.1.2 Mission statement........................................................................................................................32.1.3 Values............................................................................................................................................32.1.4 Goal statement.............................................................................................................................32.1.5 Objective statement.................................................................................................................... 32.2 Gap Analysis................................................................................................................................ 32.2.1 Gap Item.......................................................................................................................................32.2.2 Gap item 2....................................................................................................................................42.3 Organizational Environment Analysis....................................................................................... 42.4 Work Environment Analysis....................................................................................................... 42.4.1 Managerial support..................................................................................................................... 42.4.2 Physical aspects of site..............................................................................................................42.4.3 Social aspects of site..................................................................................................................42.4.4 Special factors............................................................................................................................. 42.5 Performer Analysis...................................................................................................................... 42.5.1 Job title......................................................................................................................................... 42.5.2 Job code....................................................................................................................................... 42.5.3 Education level.............................................................................................................................52.5.4 Age................................................................................................................................................ 52.5.5 Professional background............................................................................................................52.5.6 Knowledge.................................................................................................................................... 52.5.7 Skills.............................................................................................................................................. 52.5.8 Abilities..........................................................................................................................................52.5.9 Attitude.......................................................................................................................................... 53 Cause Analysis............................................................................................................................ 53.1 Environmental Factor.................................................................................................................. 53.1.1 Data............................................................................................................................................... 53.1.2 Resources.....................................................................................................................................53.1.3 Incentives......................................................................................................................................53.2 Internal Factor..............................................................................................................................53.2.1 Knowledge.................................................................................................................................... 53.2.2 Capacity........................................................................................................................................ 53.2.3 Motives..........................................................................................................................................6


S1000DBIKE-AAA-D00-00-00-00AA-952A-T-H31A


Applicable to:

4 Intervention Definition..................................................................................................................64.1 Non-Training Interventions.........................................................................................................64.1.1 Performance support...................................................................................................................64.1.2 Job design.................................................................................................................................... 64.1.3 Personal development................................................................................................................ 64.1.4 Human resource development...................................................................................................64.1.5 Organizational communication...................................................................................................64.1.6 Organizational design................................................................................................................. 64.2 Training Interventions................................................................................................................. 64.2.1 Target Audience.......................................................................................................................... 64.2.2 Prerequisites.................................................................................................................................74.2.3 Required Entry Behaviors.......................................................................................................... 74.2.4 Training Component....................................................................................................................74.2.5 Assessment Strategy.................................................................................................................. 74.2.6 Technical Requirements.............................................................................................................85 Intervention Implementation....................................................................................................... 96 Performance Evaluation..............................................................................................................96.1 Formative Evaluation...................................................................................................................96.2 Summative Evaluation................................................................................................................ 96.2.1 Immediate performance competence....................................................................................... 96.2.2 Job transfer.................................................................................................................................. 96.2.3 Organizational impact................................................................................................................. 9


References


None

Table 1 References

Learning plan

1 Basic Bike AwarenessThis learning is sponsored by the National Bike Courier association.

1.1 National Bike Courier Association (NBCA)The NBCA's mission statement is to promote unity and solidarity within the messenger communityand to raise the status of our profession.

1.2 Getting to Know Your BikeThis lesson plan describes the learning needs and instructional strategies for teaching the parts ofa bike and bike maintenance.

1.3 Course Identification NumberN00174-05-D-0003


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1.4 Modification DateN/A

1.5 Delivery Date20091228

1.6 Learning Plan Subject MatterBike description and general maintenance

2 Performance AnalysisA study was conducted at Speedy Couriers using a proformance analysis model for goals drivenmeasurements.

2.1 Organizational AnalysisThe following information describes the organizational elements of the performance analysis

2.1.1 Vision statementWe help the businesses of the city be more productive and successful by providing the fastest,most convenient courier services: From your door to theirs in less time.

2.1.2 Mission statementTo become the number one messenger service in the city by consistently providing fast,convenient service at a competitive price with 98% customer satisfaction.

2.1.3 ValuesCouriers should be goal oriented. They must exhibit the desire to meet the organization'sexpectations by completing their job tasks as assigned. The company believes this can beaccomplished more effectively if couriers take and pass the Bike course.

2.1.4 Goal statementProvide training so that couriers can maintain their own bikes and avoid breakdowns. This allowsthe couriers the ability to make more pick-ups and deliveries.

2.1.5 Objective statementManagers at Speedy Couriers, Inc. have concerns regarding their new couriers' abilities tomaintain their bikes. Because couriers supply their own bikes, the company has no idea of eachbike's condition. In order for couriers to do their jobs effectively, their bikes must be in goodworking order.

2.2 Gap AnalysisRecently, there has been a rise in calls for "breakdown" pickups, because the couriers do not knowhow to fix mechanical failures. This problem leads to increased workload on other carriers and latedeliveries and pickups, which in turn leads to unsatisfied customers.

2.2.1 Gap ItemMany couriers do not know how to correct mechanical problems with the bike's steering system.

2.2.1.1 Job task analysis itemDescribe the steps for installing and removing a bike's steering system.




Applicable to:

2.2.2 Gap item 22.2.2.1 Desired performance statement

Maintains bike in good working order. Troubleshoots breakdowns in a timely manner. Conductsrepairs at the time of breakdown.

2.2.2.2 Actual performance statementUnable to maintain bike in good working order. Cannot troubleshoot breakdowns in a timelymanner. Not able to conduct repairs at the time of breakdown.

2.2.2.3 Job task analysis itemIdentify the parts of a bike's steering system.

2.2.2.4 Gap statementBike couriers do not have the knowledge or skills needed to maintain a bicycle or the ability totroubleshoot and address problems when they occur.

2.3 Organizational Environment AnalysisAn organizational analysis was conducted on Speedy Couriers. This appraisal was aimed atidentifying areas of inefficiency and opportunities for streamlining and reorganization.

2.4 Work Environment AnalysisThe environment in which bike couriers work is typically outside, where the courier and his or herbike are subject to atmospheric conditions such as sun, rain, sleet, snow, etc. Bike maintenancewill most likely be performed inside the courier's dwelling or a garage.

2.4.1 Managerial supportSpeedy Couriers has one general managers and four shift managers. The managers work inconjunction with each other.

2.4.2 Physical aspects of siteThe physical site survey revealed that the interior layout of the Speedy Couriers facility providedample room and features to accommodate the number of couriers employed as well as anymaintenance or repair that is required.

2.4.3 Social aspects of siteIt was revealed during the survey of the social aspects of Speedy Couriers that there was very littlesocial interaction due to the nature of the work as well as the high turn over rate.

2.4.4 Special factorsNot Applicable

2.5 Performer AnalysisSkill levels for entry level bike couriers can vary from none to novice experience levels, whichrange from 0 to 1 year in service. Couriers have typically learned the skills needed through trial anderror.

2.5.1 Job titleBicycle Courier

2.5.2 Job codeNot Applicable


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2.5.3 Education levelHigh school diploma, some college

2.5.4 AgeAdults aged 18 to 21

2.5.5 Professional backgroundThe target audience for this course includes bike couriers who are responsible maintaining theirown bicycles.

2.5.6 KnowledgeGeneral bike functions, simple maintenance

2.5.7 SkillsThe audience has little to no experience with bike maintenance. Skills are mainly in bike operation.

2.5.8 AbilitiesNot Applicable

2.5.9 AttitudeBike couriers must ensure that their bikes are in safe working order for them to perform their jobseffectively.

3 Cause AnalysisA causal factor tree analysis was conducted on the Speedy Couriers, Inc.

3.1 Environmental FactorThe environmental factors were derived from examining the workplace, resources and anycompany incentives that may have an impact on the gap.

3.1.1 DataNot Applicable

3.1.2 ResourcesCouriers are provided all of the resources needed to maintain and repair their bikes.

3.1.3 IncentivesThe study revealed that there is currently a negative incentive to troubleshoot and repair bikeproblems while on courier duties. Since the company provides unlimited breakdown service thereis no reason for couriers to repair their own bikes.

3.2 Internal FactorThe internal factors were derived from interviews with the couriers.

3.2.1 KnowledgeOnly a small percentage of the couriers had the necessary knowledge needed to maintain andrepair bicycles.

3.2.2 CapacityAll of the couriers possessed the capacity to learn the skills needed to maintain and repairbicycles.




Applicable to:

3.2.3 MotivesNot Applicable

4 Intervention DefinitionThe following information outlines the recommendations for addressing the identified gap.

4.1 Non-Training InterventionsThe following information outlines the non-training recommendations for addressing the identifiedgap.

4.1.1 Performance supportNot Applicable

4.1.2 Job designTwo changes will be made regarding courier responsibilities. First couriers will not receive thecommission for a delivery if the breakdown service is used and the repair could have been madewithout pick-up. Second, bonuses will be provided to couriers that do not use the breakdownservice.

4.1.3 Personal developmentNot Applicable

4.1.4 Human resource developmentCurrent employees will be required to successfully complete the courseware within 30 calendardays of implementation. All subsequent hires will be required to complete the courseware within 30calendar days of hire date.

4.1.5 Organizational communicationNot Applicable

4.1.6 Organizational designAll managers will be required to complete the same courseware training as the couriers.

4.2 Training InterventionsThe following information outlines the training recommendations for addressing the identified gap.

4.2.1 Target AudienceSkill levels for entry level bike couriers can vary from none to novice experience levels, whichrange from 0 to 1 year in service. Couriers have typically learned the skills needed through trial anderror.

4.2.1.1 Current entry behaviorsThe majority of couriers have high school educations and have basic knowledge of tool use.

4.2.1.2 Attitude toward contentA survey revealed that 95% of the couriers are willing to complete training as long as the statedincentives are employed.

4.2.1.3 Learning preferencesNot Applicable


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4.2.2 PrerequisitesNot Applicable

4.2.3 Required Entry BehaviorsNot Applicable

4.2.4 Training ComponentThe following information outlines the training component.

4.2.4.1 Training typeAn online computer-based course will be used in conjunction with hands on practices.

4.2.4.2 Learning strategyThis training uses a blended approach to teaching bicycle maintenance and repair.

4.2.4.34.2.4.3.1 Time

The computer-based courseware will take approximately 1.5 hours to complete. The practicalexercises will take approximately 2 hours to complete.

4.2.4.4 Required financesAll financial requirements will be covered by Speedy Couriers, Inc.

4.2.4.5 Required personnelThe current bicycle repair technician will serve as a facilitator during the practical exercise portionof the training as well as the grader for the hands-on test at the end of the training.

4.2.4.6 Required facilitiesThe current bicycle repair area will be used for the practical exercises and end of training hands-on test.

4.2.4.7 Required equipmentCouriers may take the computer portion of the training using one of Speedy Courier's officecomputer workstations or they may take a CD of the training to be completed at home. The currentbicycle repair equipment will be used for the practical exercises and end of training hands-on test.

4.2.4.8 Local culture considerationsNot Applicable

4.2.5 Assessment StrategyThe following information outlines the assessment strategies for the Basic Bike Awareness course.

4.2.5.1 Computer-based Assessment ComponentThe following information outlines the assessment strategy for the computer based portion of thetraining

4.2.5.1.1 Mastery score criteria80% mastery of all lesson tests

4.2.5.1.2 Performance rubricA rubric is provided with the courseware documentation.

4.2.5.1.3 Scoring methodThe lesson tests are scored using computer programing built into the training




Applicable to:

4.2.5.1.4 Minimum pass thresholdNot Applicable

4.2.6 Technical RequirementsThis section lists the technical requirements needed to complete the instruction.

4.2.6.1 BrowsersThis courseware is created to run in the Internet Explorter 6.x web browser.

4.2.6.2 LMSLesson content packages will be tracked in the Sum Total LMS.

4.2.6.3 Non-LMS environmentThe courseware does not require any special considerations when it is running outside of an LMS.

4.2.6.4 Paper based materialsNot Applicable

4.2.6.5 ClassroomInstruction will be taken in the Learning Lab at Speedy Courier's main office. The training is part ofthe employee's first day orientation and is required. No courier assignements will be given until theemployee completes the orientation and the training.

4.2.6.6 On-the-job trainingThere are no technical requirements for OJT.

4.2.6.7 AccessibilityThis courseware meets W3C Web Accessibility Initiative Guidelines Priority 1 checkpoints

4.2.6.8 PlayersThe courseware will make use of the following players and plug-ins: Adobe Flash Player andAcrobat Acrobat Reader

4.2.6.9 Graphic standardsGraphics utilized are JPEGs and SWF files. SWF files may contain 3D animation or interactivity.SWF files are being utilized in lieu of CGM files to reach a broader audience because they can beviewed utilizing the Adobe Flash Player.

4.2.6.10 ViewersNot Applicable

4.2.6.11 ResolutionAlthough the courseware can be viewed using different resolutions, it is best viewed in 1024x768resolution

4.2.6.12 File size limitationsThis courseware keeps it file size to the bare minimum. It tries to keep all files below 100k. If somefiles are larger than the 100k a pre-loader is attached.

4.2.6.13 Download timeDownload time will vary due to the the users computer specifications.


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4.2.6.14 SecuritySecurity level is unclassified.

5 Intervention ImplementationThe implementation of this intervention will comprise of the creation and institution of a computer-based training program that works in conjunction with hands-on practical exercizes.

6 Performance EvaluationThe following information outlines the Performance evaluation.

6.1 Formative EvaluationThe formative evaluation will be conducted using surveys

6.2 Summative EvaluationThe summative evaluation will be conducted using surveys as well as the analysis of assessmentresults

6.2.1 Immediate performance competenceNot Applicable

6.2.2 Job transferNot Applicable

6.2.3 Organizational impactNot Applicable

End of data module


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S1000DBIKE-AAA-DA0-00-00-00AA-041A-T-T61EApplicable to:


Wheels

Description of how it is made: Knowledge Check

Table of contents PageDescription of how it is made: Knowledge Check.................................................................................. 1References................................................................................................................................................... 1Learning assessment..................................................................................................................................11 Interaction..................................................................................................................................... 11.1 Drag-and-Drop............................................................................................................................. 1


References


None

Table 1 References

Learning assessment

Drag-and-Drop Assessment Question

1 Interaction1.1 Drag-and-Drop

Type: ......................................................................... Drag and drop

QuestionDrag the answer options to the matching questions, and then click CHECK

Which part of the hub assembly allows wheelcomponents to rotate freely around the axle?

Bearings

To which part of the assembly are the spokesattached?

Hub shell

Which part of the hub assembly is attached tothe dropouts?

Axle

End of data module


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S1000DBIKE-AAA-DA0-10-20-00AA-520A-T-T4JCApplicable to:


Front wheel

Remove procedures: Interactive content - Procedure

Table of contents PageRemove procedures: Interactive content - Procedure............................................................................1References................................................................................................................................................... 1Learning content..........................................................................................................................................1Instruction..................................................................................................................................................... 1


List of figuresFig 1 ....................................................................................................................................................... 1Fig 2 ....................................................................................................................................................... 2Fig 3 ....................................................................................................................................................... 2Fig 4 ....................................................................................................................................................... 3Fig 5 ....................................................................................................................................................... 3

References


None

Table 1 References

Learning content

Front Wheel RemovalThe content of this data model describes the steps for removing the bicycle front wheel.

InstructionICN-S1000DBIKE-AAA-DA00000-A-06RT9-00094-A-001-01

Fig 1

11.1 To remove your bike's front wheel, place the bike on a stand. If you do not have a stand, you can

still remove the tire. It will just take a little coordination on your part.




Applicable to:

Begin by either deflating the front tire slightly or disconnecting the front brakes. This is done so thewheel can come out easily and not get stuck at the brake pads.

ICN-S1000DBIKE-AAA-DA00000-A-06RT9-00106-A-001-01Fig 2

1.2 If your bike has a quick-release lever, push the lever outward and turn it in a counterclockwisemotion for several revolutions.


1.3 If your bike does not have a quick-release lever, you will need a wrench to loosen the nuts oneither side of the hub.


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S1000DBIKE-AAA-DA0-10-20-00AA-520A-T-T4JCApplicable to:



1.4 Remove the wheel.


Use the arrows to view the slide show.

End of data module


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S1000DBIKE-AAA-DA2-10-00-00AA-041A-T-T62EApplicable to:


Steering

Description of how it is made: Knowledge Check

Table of contents PageDescription of how it is made: Knowledge Check.................................................................................. 1References................................................................................................................................................... 1Learning assessment..................................................................................................................................11 Interaction..................................................................................................................................... 11.1 Question........................................................................................................................................1


References


None

Table 1 References

Learning assessment

Knowledge Check

1 Interaction1.1 Question

Type: ......................................................................... Single select

QuestionSelect your answer, and then click CHECK.

The stem attaches the _________________________ to the ________________________.

Answers■ headset / fork

Feedbacks– Attempt match: 1

The answer "headset / fork" is incorrect. Try again!

– Attempt match: 2The answer "headset / fork" is incorrect. The correct answer is handlebar / headset.

■ fork / handlebar





Applicable to:

The answer "fork / handlebar" is incorrect. Try again!

– Attempt match: 2The answer "fork / handlebar" is incorrect. The correct answer is handlebar / headset.

■ handlebar / headset

Feedbacks– Correct!

■ frame / handlebar


The answer "frame / handlebar" is incorrect. Try again!

– Attempt match: 2The answer "frame / handlebar" is incorrect. The correct answer is handlebar / headset.

End of data module


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Bicycle

Illustrated Parts Data - IPD

ICN-S1000DBIKE-AAA-D000000-0-U8025-00536-B-04-1Fig 1 Bicycle

Initial provisioning project informationIPP number: ............................................................. KZ9990001IPP subject: ..............................................................BICYCLEIPP file identifier: ......................................................s


MY CAVEAT

S1000DBIKE-AAA-D00-00-00-01AA-941A-D




Catalog sequence numbers

Fig Item UPA /UI

CAGE Identification Nomenclature ∗UCE / ∘UCA•MV / ‣Effect

ICY

01/A 000 REF KZ999 BICYCLE-001 Bicycle •MB01/A 001 1 / EA KZ999 BICYCLE-001/1 * Frame assembly •MB01/A 002 1 / EA KZ999 BICYCLE-001/2A ** Seat, assembly •MB

1 / EA KZ999 BICYCLE-001/2B ** Cruiser Seat, assembly •MB01/A 003 1 / EA KZ999 BICYCLE-001/3 ** Steering system •MB01/A 004 1 / EA KZ999 BICYCLE-001/4 ** Drive train system •MB01/A 005 1 / EA KZ999 BICYCLE-001/5 ** Brake sub-system •MB01/A 006 1 / EA KZ777 LRU1001 ** Light system •MB01/A 007 1 / EA KZ888 WH-001 ** Wheel, assembly rear •MB01/A 008 1 / EA KZ888 WH-002 ** Wheel, assembly front •MB01/A 009 1 / EA KZ888 CP-001 ** Computer •MB

End of data module

UNCLASSIFIEDcv56


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S1000DBIKE-AAA-D00-00-00-00AA-00XA-AApplicable to:All


Bicycle

Controls and Indicators

General information

1 IntroductionThe following table(s) and illustration(s) provide the description and use of the controls andindicators pertaining to the mountain bicycle(s). Some controls and indicators may differdepending on the model.

ICN-07GB6-BIKECI0001-001-01Fig 1 Bicycle Controls and Indicators

1 Control or indicator groupReferences: .............................................................. Fig 1

S1000DBIKE-C3002-LOAP1-00 UNCLASSIFIEDcv56

S1000DBIKE-AAA-D00-00-00-00AA-00XA-A


Applicable to:All

1.1 ci-0001Key: ........................................................................... 1Name: ........................................................................LED TaillightDescription

Control or indicator functions:– Lights illuminate automatically when brakes are engaged.

1.2 ci-0002Key: ........................................................................... 2Name: ........................................................................Chrome BellDescription

Control or indicator functions:– Press to sound bell. Normally used to signal a need for attention.

1.3 ci-0003Key: ........................................................................... 3Name: ........................................................................LED HeadlightDescription

Control or indicator functions:– Push button to turn light on or off.

1.4 ci-0004Key: ........................................................................... 4Name: ........................................................................Platform PedalsDescription

Control or indicator functions:– Control the acceleration of the bicycle.

End of data module


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BRAKE-AAA-D00-00-00-00AA-00WA-DApplicable to:All


Mountain bicycle


Table of contents PageApplicability cross-reference table............................................................................................................ 1References................................................................................................................................................... 1Applicability cross-reference table............................................................................................................ 1

List of tablesTable 1 References....................................................................................................................................1Table 2 Product attribute list.................................................................................................................... 1

References


None

Table 1 References


Name

Display name (Id)


Value pattern

Values

Brake serial numberB/SN (serialno)

Serial number by brake

Model(model)

The model of the brake BR01|BR02SS-11

Table 2 Product attribute list

End of data module


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BRAKE-AAA-DA1-00-00-00AA-041A-AApplicable to:serialNo: 0001-0008 and model:BR01


Brake system


Table of contents PageDescription of how it is made....................................................................................................................1References................................................................................................................................................... 1Description....................................................................................................................................................11 Brake system............................................................................................................................... 11.1 Cantilever brake...........................................................................................................................11.2 Brake pads................................................................................................................................... 41.3 Brake lever................................................................................................................................... 6


List of figuresFig 1 Cantilever brake with straddle cable........................................................................................ 3Fig 2 Exploded diagram of a brake.................................................................................................... 5Fig 3 Typical components of a mountain bicycle lever.................................................................... 7

References


None

Table 1 References

Description

1 Brake systemThe most important part of the bicycle is the brake system. Only a minimum maintenance of thebrake system is necessary. But, when a problem does occur, make sure you to do the necessarymaintenance as quickly as possible. If you do not do this the bicycle will be dangerous to use.

There are nine different types of brake systems. The one found on most bicycles is the cantileverbrake (refer to Para 1.1).

1.1 Cantilever brakeThe brake system (refer to Fig 1) has these primary components:

the brake lever (refer to Para 1.3)the brake cablethe brake arm


MY CAVEAT

BRAKE-AAA-DA1-00-00-00AA-041A-A


Applicable to:serialNo: 0001-0008 and model:

BR01

the brake clamp (also known as callipers)the brake pads (refer to Para 1.2)


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00512-A-04-1Fig 1 Cantilever brake with straddle cable


MY CAVEAT




BR01

A cable that goes from the brake levers on the handlebars pulls the two levers on the brakestogether. This presses the brake pads against the outer rim of the wheel, which decreases thespeed of the bicycle.

1.2 Brake padsThere are four brake pads (refer to Fig 2) on the bicycle. Two are found on the front wheel and twoon the rear wheel. The brake pads are made out of hard wearing rubber. The pads press againstthe rim of the wheel to cause friction when the you operate the brake levers.


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00513-A-04-1Fig 2 Exploded diagram of a brake


MY CAVEAT




BR01

1.3 Brake leverThe brake levers (refer to Fig 3) are easily damaged. The lever is installed in the mount. A clampbolt holds the mount. This bolt is not visible because it is found in the mount. The lever turns on alever pivot bolt. The adjuster lock nut holds the brake cable. This lock nut adjusts the tension of thecable.


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ICN-S1000DBIKE-AAA-DA10000-0-U8025-00514-A-04-1Fig 3 Typical components of a mountain bicycle lever


MY CAVEAT




BR01

The left brake lever holds the brake pads on the front wheel and the right brake pads hold thebrakes on the rear wheel.

End of data module


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BRAKE-AAA-DA1-10-00-00AA-251A-AApplicable to:serialNo: 0010, 0023, 0056-0062 andmodel: BR02


Brake pads

Clean with rubbing alcohol

Table of contents PageClean with rubbing alcohol.........................................................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References



Table 1 References


Required conditions


None



MY CAVEAT



Applicable to:serialNo: 0010, 0023, 0056-0062 and

model: BR02

Required persons




Support equipment


None






Spares


None

Table 6 Spares


Procedure1 Do a visual inspection of the brakes as given in the pre-ride checks (refer to S1000DBIKE-AAA-

D00-00-00-00AA-121A-A).

2 Clean the brake pads.

2.1 Find each of the brake pads.

2.2 Apply a thin layer of the Rubbing alcohol on each of the brake pads.


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BRAKE-AAA-DA1-10-00-00AA-251A-AApplicable to:serialNo: 0010, 0023, 0056-0062 andmodel: BR02


2.3 Rub the surface until you have applied the Rubbing alcohol to the complete surface of the pad.

2.4 Remove the unwanted alcohol.


Required conditions


None


End of data module


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BRAKE-AAA-DA1-00-00-00AA-341A-AApplicable to:serialNo: 0111 and model: SS-11


Brake system

Manual test



References


None

Table 1 References


Required conditions


None



MY CAVEAT



Applicable to:serialNo: 0111 and model: SS-11

Required persons




Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Put the bicycle in a vertical position.

2 Hold the handle bars and push the bicycle forwards.

3 Apply the brakes.

4 Make sure that the wheels lock and the bicycle stops.


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BRAKE-AAA-DA1-00-00-00AA-341A-AApplicable to:serialNo: 0111 and model: SS-11



Required conditions


None


End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-040A-AApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Electrical system

Description of how it is made and its function

Table of contents PageDescription of how it is made and its function........................................................................................ 1References................................................................................................................................................... 1Description....................................................................................................................................................11 Lighting system............................................................................................................................1


List of figuresFig 1 Lighting system............................................................................................................................2

References


None

Table 1 References

Description

1 Lighting systemThe illustration that follows (see Fig 1) shows the lighting system of the bicycle.


MY CAVEAT

S1000DLIGHTING-AAA-D00-00-00-00AA-040A-A




ICN-S1000DBIKE-AAA-DA24000-0-C0419-12345-A-04-1Fig 1 Lighting system

End of data module


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Lights

Manual test



References


None

Table 1 References


Required conditions


None



MY CAVEAT





Required persons




Support equipment


None




None


Spares


None

Table 6 Spares


Procedure1 Set the lights to on.

2 Make sure that all the lights operate correctly.


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Required conditions


None


End of data module


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Lights

Observed fault


NYCJD02 The lights are set to the dim position.

Table of contents PageObserved fault............................................................................................................................................. 1References................................................................................................................................................... 1Fault reporting..............................................................................................................................................1Preliminary requirements............................................................................................................................1

List of tablesTable 1 References....................................................................................................................................1Table 2 Required conditions.................................................................................................................... 1Table 3 Support equipment......................................................................................................................2Table 4 Consumables, materials and expendables.............................................................................. 2Table 5 Spares...........................................................................................................................................2

References


S1000DLIGHTING-AAA-D00-00-00-00AA-341A-A Lights — Manual testS1000DLIGHTING-AAA-D00-00-00-00AA-921A-A Lighting — Remove and install a new item

Table 1 References

Fault reporting


Required conditions


None



MY CAVEAT





Support equipment


None




None


Spares


None

Table 5 Spares

Safety conditions

WARNINGMake sure that the bulb is cool before you replace it.

WARNINGMake sure the light glass is not broken before handling it


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Fault codeNYCJD02

Fault descriptionThe lights are set to the dim position.

1 During use or maintenance1.1 Fault isolation test – LRU



Bulb Part: KZ111/PN LiRUs-L1-11

Fault isolation test performanceTest type: ......................................................... OperationTest code: ........................................................ O-001

Test descriptionName: ............................................................... Test the bulbs

Test parametersfrom 1 to 1 Days

Test procedures: ..........................................S1000DLIGHTING-AAA-D00-00-00-00AA-341A-A

Repair procedures: .............................................. S1000DLIGHTING-AAA-D00-00-00-00AA-921A-A

RemarksThis is the data module you would visit when you notice that the lights do not operate correctly.

End of data module


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Lighting

Assemble, install and connect procedures

Table of contents PageAssemble, install and connect procedures..............................................................................................1References................................................................................................................................................... 1Preliminary requirements............................................................................................................................1Procedure..................................................................................................................................................... 2Requirements after job completion...........................................................................................................3


References


S1000DLIGHTING-AAA-D00-00-00-00AA-921A-A Lighting — Remove and install a new itemS1000DLIGHTING-AAA-D00-00-00-00AA-941A-D —

Table 1 References


Production management dataZone 200

300

Required conditions


Bike is stationary



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Support equipment


BSK-TLST-001 1 EA




None


Spares


None

Table 5 Spares


Procedure1 Impacted zones:Zone 200 and Zone 300

2 S1

3 ELO-Box

4 Remove the lighting system from the packaging.

5 Make sure that the components in the package are the same as those on the S1000DLIGHTING-AAA-D00-00-00-00AA-941A-D

6 Install the light bulb to the front and rear lights (refer to S1000DLIGHTING-AAA-D00-00-00-00AA-921A-A).

7 Attach the front light fitting on the top of the handlebar.


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7.1 Apply the protective strip around the handlebar.

7.2 Pull the clamp open and put it around the protective strip with the light connector at the top.

7.3 Install the washer on the screw.

7.4 Use the correct screwdriver from the and tighten the screw into the hole at the bottom of theclamp. This safeties the clamp to the handlebar.

8 Attach the rear light fitting to the rear triangle of the bike frame.

8.1 Apply the protective strip around one of the two rear triangle up-tubes.

8.2 Pull the clamp open and put it around the protective strip. Make sure the light connector pointsrearwards.

8.3 Install the washer on the screw.

8.4 Use the correct screwdriver from the and tighten the screw into the hole at the bottom of theclamp. This safeties the clamp to the tube.

9 Attach the light with the white glass to the front connector.

10 Attach the light with the red glass to the rear connector.


Required conditions


None


End of data module


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Lighting




References


None

Table 1 References


Production management dataZone F11 Half frontWork location on the handlebarsZone R11 Half rearWork location under the saddle

Required conditions


Light set to offLight removed from bicycle



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Support equipment


Special Toolset 578015T01 1 EA Material set– Screwdriver BSK-SCRDV-001 1 EA




None


Spares


Bulb D00000001A010 2 EA DiscardedKit 578015B01 1 EA Material set– Bulb D00000001A020 1 EA 1

– Bulb D00000001A021 1 EA 1

Glass D00000001A022 1 EA ReferencedGlass D00000001A023 1 EA Modified from– Glass D00000001A022 1 EA

Table 5 Spares

Safety conditions


Procedure1 From location on the handlebars, remove the glass Glass.


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2 Remove the used front yellow bulb Bulb.

3 Discard the used bulb Bulb.

4 Remove the new white bulb Bulb from the kit Kit.

5 Install the new white bulb Bulb.

6 Install the glass Glass on the light.

7 Attach the light fitting on the handlebar.

8 Apply the protective strip around the handlebar.

9 Install the washer on the screw.

10 Use the special screwdriver Screwdriver from the toolset Special Toolset and tighten the screwinto the hole at the bottom of the clamp. This safeties the clamp to the handlebar.

11 From location under the saddle Remove the glass Glass.

12 Remove the used yellow rear bulb Bulb.

13 Discard the used bulb Bulb.

14 Remove the new white bulb Bulb from the kit Kit.

15 Install the new white Bulb.

16 Drill a 4mm hole in the middle of the glass Glass in order to allow venting and heat evacuationwhen the light is switched on.

The glass with the hole may be ordered independently with the reference Glass.

17 Install the glass with the hole Glass on the light.


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Required conditions


Switch the lights on if necessary.


End of data module

1 Make sure that the new bulb is not cracked.


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S1000DLIGHTING-AAA-D00-00-00-01AA-941A-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Light system

Illustrated Parts Data - IPD

ICN-S1000DBIKE-AAA-D000000-0-U8025-00537-A-04-1Fig 1 Light system

Initial provisioning project informationIPP number: ............................................................. KZ7771111IPP subject: ..............................................................LIGHT SYSTEMIPP file identifier: ......................................................s

Catalog sequence numbers

Fig Item UPA /UI


ICY

01/0 000 REF KZ777 LRU100101/0 001 1 KZ777 LRU1010 * FRONT01/0 002 1 KZ777 LRU1011 **01/0 003 1 KZ777 LRU1012 ***01/0 004 1 KZ777 LRU1013 ****01/0 005 2 KZ777 LIRUS-L1-10 ***


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S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D




Fig Item UPA /UI


ICY

01/0 006 1 KZ777 LRU1018 **01/0 007 1 KZ777 LRU1019 ***01/0 008 1 KZ777 LRU1022 ****01/0 009 1 KZ777 LRU1020 ***01/0 010 2 KZ777 LIRUS-L1-11 ****01/0 011 1 KZ777 LRU1026 **01/0 012 1 KZ777 LRU-B001 *01/0 013 1 KZ777 LRU-B003 **01/0 014 1 KZ777 LRU-B124 **01/0 015 1 KZ777 LRU-B556 **01/0 016 1 KZ777 LRU-B789 ***01/0 017 1 KZ777 LRU2010 *01/0 018 1 KZ777 LRU1011 ** REAR01/0 019 1 KZ777 LRU2018 **01/0 020 1 KZ777 LIRUS-B1-12F ***01/0 021 1 KZ777 LIRUS-B1-12R ***01/0 022 2 KZ777 LIRUS-G1-10 ***01/0 023 1 KZ777 LIRUS-G1-10H ***

(Continued)

End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-00EA-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Lighting

Functional item numbers common information repository

1 BattFunctional item number: ......................................... BattType: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxContext identification: ..............................................PN-AC-12561Manufactorer code: ................................................. F0001Originator: .................................................................ManufacturerName: ........................................................................BatteryAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................Section: 21 cm

2 C_BattFunctional item number: ......................................... C_BattType: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxContext identification: ..............................................PN-AC-12561Manufactorer code: ................................................. F0001Originator: .................................................................ManufacturerName: ........................................................................ConnectorAlternatives:Applicable to: Mountain storm Mk1– Functional item

Sealed: ............................................................. YesLocation: ...........................................................300


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S1000DLIGHTING-AAA-D00-00-00-00AA-00EA-D




3 C_BikeFunctional item number: ......................................... C_BikeType: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxName: ........................................................................ReceptacleAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................instloctyp60: 60 cm

4 DiodeFunctional item number: ......................................... DiodeType: ......................................................................... ExactInstallation identifier: ................................................d1Name: ........................................................................DiodeAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................100

5 DiodeFunctional item number: ......................................... DiodeType: ......................................................................... ExactInstallation identifier: ................................................d2Name: ........................................................................DiodeAlternatives:Applicable to: Mountain storm Mk1– Functional item



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6 ELO-BoxFunctional item number: ......................................... ELO-BoxType: ......................................................................... ExactName: ........................................................................Electronic Box 01Alternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................instloctyp60: 45 cmFamily: .............................................................. Electronic Unit

7 FT1Functional item number: ......................................... FT1Type: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxName: ........................................................................GT-002-WDAlternatives:Applicable to: Mountain storm Mk1– Functional item





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10 GenFunctional item number: ......................................... GenType: ......................................................................... ExactName: ........................................................................GeneratorAlternatives:Applicable to: Mountain storm Mk1– Functional item


11 L1Functional item number: ......................................... L1Type: ......................................................................... ExactName: ........................................................................Front lightAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................Buttock line: 55 cmFamily: .............................................................. lights


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12 L2Functional item number: ......................................... L2Type: ......................................................................... ExactName: ........................................................................Rear lightAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................

Buttock line: 30 cmFamily: .............................................................. lights

13 RelFunctional item number: ......................................... RelType: ......................................................................... ExactInstallation identifier: ................................................ELO-BOXName: ........................................................................RelayAlternatives:Applicable to: Mountain storm Mk1– Functional item


14 S1Functional item number: ......................................... S1Type: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxName: ........................................................................SwitchAlternatives:Applicable to: Mountain storm Mk1– Functional item

Normative component: ................................... YesLocation: ...........................................................Water line: 30 cm


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15 SensorFunctional item number: ......................................... SensorType: ......................................................................... ExactName: ........................................................................Speed sensorAlternatives:Applicable to: Mountain storm Mk1– Functional item


16 T01Functional item number: ......................................... T01Type: ......................................................................... ExactName: ........................................................................TachometerAlternatives:Applicable to: Mountain storm Mk1– Functional item


17 VV1Functional item number: ......................................... VV1Type: ......................................................................... ExactInstallation identifier: ................................................ELO-BoxName: ........................................................................Distribution moduleAlternatives:Applicable to: Mountain storm Mk1– Functional item


End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-00GA-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Lighting

Parts common information repository

1 LIRUS-B1-12FPart number: ............................................................ LIRUS-B1-12FManufactorer code: ................................................. KZ777Description for part: .................................................Front BulbProcurement data

Enterprises: ......................................................F0001Technical data

Part usage: ...................................................... Basic issue item

2 LIRUS-B1-12RPart number: ............................................................ LIRUS-B1-12RManufactorer code: ................................................. KZ777Description for part: .................................................Rear BulbProcurement data



3 LIRUS-G1-10Part number: ............................................................ LIRUS-G1-10Manufactorer code: ................................................. KZ777Description for part: .................................................GlassProcurement data



4 LIRUS-G1-10HPart number: ............................................................ LIRUS-G1-10HManufactorer code: ................................................. KZ777Description for part: .................................................Glass with holeProcurement data




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S1000DLIGHTING-AAA-D00-00-00-00AA-00GA-D




5 LIRUS-L1-10Part number: ............................................................ LIRUS-L1-10Manufactorer code: ................................................. KZ777Description for part: .................................................BatteryProcurement data


Part usage: ...................................................... Basic issue itemSpecial storage: .............................................. Yes

6 LIRUS-L1-11Part number: ............................................................ LIRUS-L1-11Manufactorer code: ................................................. KZ777Description for part: .................................................BulbProcurement data



7 LIRUs-L1-11Part number: ............................................................ LIRUs-L1-11Manufactorer code: ................................................. KZ111Description for part: .................................................BulbProcurement data



8 LRU-B001Part number: ............................................................ LRU-B001Manufactorer code: ................................................. KZ777Description for part: .................................................Bracket, light mountingProcurement data


Part usage: ...................................................... Basic issue itemSpecial storage: .............................................. No


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9 LRU-B003Part number: ............................................................ LRU-B003Manufactorer code: ................................................. KZ777Description for part: .................................................ClipProcurement data



10 LRU-B124Part number: ............................................................ LRU-B124Manufactorer code: ................................................. KZ777Description for part: .................................................Screw,specialProcurement data



11 LRU-B556Part number: ............................................................ LRU-B556Manufactorer code: ................................................. KZ777Description for part: .................................................Washer,flatProcurement data



12 LRU-B789Part number: ............................................................ LRU-B789Manufactorer code: ................................................. KZ777Description for part: .................................................Grip,stripProcurement data




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13 LRU1001Part number: ............................................................ LRU1001Manufactorer code: ................................................. KZ777Description for part: .................................................Light systemProcurement data



14 LRU1010Part number: ............................................................ LRU1010Manufactorer code: ................................................. KZ777Description for part: .................................................Light, sub-assembly frontProcurement data



15 LRU1011Part number: ............................................................ LRU1011Manufactorer code: ................................................. KZ777Description for part: .................................................Light, main bodyProcurement data



16 LRU1012Part number: ............................................................ LRU1012Manufactorer code: ................................................. KZ777Description for part: .................................................Light, baseProcurement data




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17 LRU1013Part number: ............................................................ LRU1013Manufactorer code: ................................................. KZ777Description for part: .................................................SealProcurement data



18 LRU1018Part number: ............................................................ LRU1018Manufactorer code: ................................................. KZ777Description for part: .................................................Lens, assemblyProcurement data



19 LRU1019Part number: ............................................................ LRU1019Manufactorer code: ................................................. KZ777Description for part: .................................................Lens sub-assemblyProcurement data



20 LRU1020Part number: ............................................................ LRU1020Manufactorer code: ................................................. KZ777Description for part: .................................................ReflectorProcurement data




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21 LRU1022Part number: ............................................................ LRU1022Manufactorer code: ................................................. KZ777Description for part: .................................................SealProcurement data



22 LRU1026Part number: ............................................................ LRU1026Manufactorer code: ................................................. KZ777Description for part: .................................................Loom wiringProcurement data



23 LRU2010Part number: ............................................................ LRU2010Manufactorer code: ................................................. KZ777Description for part: .................................................Light, sub assembly rearProcurement data



24 LRU2018Part number: ............................................................ LRU2018Manufactorer code: ................................................. KZ777Description for part: .................................................Lens, assembly rearProcurement data



End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-00HA-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Lighting

Zones common information repository

1 100Type: ......................................................................... Major zoneZone number: ...........................................................100contains: ....................................................................110Alternatives:Applicable to: Brook trekker Mk9– Zone

Description: ...................................................... FRONT ZONE BEGINS BY FRONT TIRE. ITSTARTS FROM LENGTH "0 cm" TO LENGTH"50 cm"

2 110Type: ......................................................................... SubzoneZone number: ...........................................................110belongsto: ................................................................. 100Alternatives:Applicable to: Brook trekker Mk9– Zone

Description: ...................................................... TIRE ZONE INCLUDING THE FRONT TIRE,THE INNER TUBE AND THE SPOKES

3 200Type: ......................................................................... Major zoneZone number: ...........................................................200Alternatives:Applicable to: Brook trekker Mk9– Zone

Description: ...................................................... MIDDLE ZONE. IT STARTS FROM LENGTH"50 cm" TO LENGTH "100 cm"


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S1000DLIGHTING-AAA-D00-00-00-00AA-00HA-D




4 300Type: ......................................................................... Major zoneZone number: ...........................................................300Alternatives:Applicable to: Mountain storm Mk1– Zone

Description: ...................................................... BACK ZONE. IT STARTS FROM LENGTH "100cm" TO LENGTH "150 cm"

End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-00NA-DApplicable to:Mountain bicycle and (Mountainstorm Mk1 or Brook trekker Mk9)


Lighting

Support equipment common information repository

1 BSK-TLST-001Tool number: ............................................................BSK-TLST-001Manufactorer code: ................................................. KZ666Description for part: .................................................Specialist toolset DescrShort name: ..............................................................Specialist toolsetProcurement dataTechnical data

Quantity: ........................................................... 1Alternatives:– Tool

Description: ...................................................... Specialist toolset Descr

2 BSK-TLST-001-01Tool number: ............................................................BSK-TLST-001-01Manufactorer code: ................................................. KZ666Description for part: .................................................Tire pressure gauge DescrShort name: ..............................................................Tire pressure gaugeProcurement dataTechnical data


Description: ...................................................... Tire pressure gauge Descr

3 BSK-TLST-001-02Tool number: ............................................................BSK-TLST-001-02Manufactorer code: ................................................. KZ666Description for part: .................................................Stiff bristle brus DescrShort name: ..............................................................Stiff bristle brushProcurement dataTechnical data


Description: ...................................................... Stiff bristle brush Descr


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S1000DLIGHTING-AAA-D00-00-00-00AA-00NA-D




4 BSK-TLST-001-03Tool number: ............................................................BSK-TLST-001-03Manufactorer code: ................................................. KZ666Description for part: .................................................Chain cleaning tool DescrShort name: ..............................................................Chain cleaning toolProcurement dataTechnical data


Description: ...................................................... Chain cleaning tool Descr

5 BSK-TLST-001-04Tool number: ............................................................BSK-TLST-001-04Manufactorer code: ................................................. KZ666Description for part: .................................................Tire lever DescrShort name: ..............................................................Tire leverProcurement dataTechnical data


Description: ...................................................... Tire lever Descr

6 BSK-TLST-001-05Tool number: ............................................................BSK-TLST-001-05Manufactorer code: ................................................. KZ666Description for part: .................................................Foot pump DescrShort name: ..............................................................Foot pumpProcurement dataTechnical data


Description: ...................................................... Foot pump Descr


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7 BSK-TLST-001-07Tool number: ............................................................BSK-TLST-001-07Manufactorer code: ................................................. KZ666Description for part: .................................................Marker pen DescrShort name: ..............................................................Marker penProcurement dataTechnical data


Description: ...................................................... Marker pen Descr

8 BSK-TLST-001-07Tool number: ............................................................BSK-TLST-001-07Manufactorer code: ................................................. KZ666Description for part: .................................................Tube patch kit DescrShort name: ..............................................................Tube patch kitProcurement dataTechnical data


Description: ...................................................... Tube patch kit Descr

9 BSK-TLST-001-08Tool number: ............................................................BSK-TLST-001-08Manufactorer code: ................................................. KZ666Description for part: .................................................8mm Allen wrench DescrShort name: ..............................................................8mm Allen wrenchProcurement dataTechnical data


Description: ...................................................... 8mm Allen wrench Descr


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10 BSK-TLST-001-09Tool number: ............................................................BSK-TLST-001-09Manufactorer code: ................................................. KZ666Description for part: .................................................Water hose DescrShort name: ..............................................................Water hoseProcurement dataTechnical data


Description: ...................................................... Water hose Descr

11 BSK-TLST-001-11Tool number: ............................................................BSK-TLST-001-11Manufactorer code: ................................................. KZ666Description for part: .................................................Sponge DescrShort name: ..............................................................SpongeProcurement dataTechnical data


Description: ...................................................... Sponge Descr

12 BSK-TLST-001-12Tool number: ............................................................BSK-TLST-001-12Manufactorer code: ................................................. KZ666Description for part: .................................................Clean dry cloth DescrShort name: ..............................................................Clean dry clothProcurement dataTechnical data


Description: ...................................................... Clean dry cloth Descr


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13 BSK-TLST-001-13Tool number: ............................................................BSK-TLST-001-13Manufactorer code: ................................................. KZ666Description for part: .................................................Set of Allen wrenches DescrShort name: ..............................................................Set of Allen wrenchesProcurement dataTechnical data


Description: ...................................................... Set of Allen wrenches Descr

14 BSK-TLST-999-01Tool number: ............................................................BSK-TLST-999-01Manufactorer code: ................................................. KZ666Description for part: .................................................Test stand DescrShort name: ..............................................................Test standProcurement dataTechnical data


Description: ...................................................... Test stand Descr

15 HSP-D001Tool number: ............................................................HSP-D001Manufactorer code: ................................................. HS111Description for part: .................................................Extra firm hold hairspray DescrShort name: ..............................................................Extra firm hold hairsprayProcurement dataTechnical data


Description: ...................................................... Extra firm hold hairspray Descr


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16 LL-003Tool number: ............................................................LL-003Manufactorer code: ................................................. KZ222Description for part: .................................................Chain cleaning fluid DescrShort name: ..............................................................Chain cleaning fluidProcurement dataTechnical data

Quantity: ........................................................... As requiredAlternatives:– Tool

Description: ...................................................... Chain cleaning fluid Descr

17 PPP-001Tool number: ............................................................PPP-001Manufactorer code: ................................................. KK999Description for part: .................................................Floor covering DescrShort name: ..............................................................Floor coveringProcurement dataTechnical data


Description: ...................................................... Floor covering Descr

18 Stand-001Tool number: ............................................................Stand-001Manufactorer code: ................................................. KZ666Description for part: .................................................Work stand DescrShort name: ..............................................................Work standProcurement dataTechnical data


Description: ...................................................... Work stand Descr

End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-0A1A-DApplicable to:All


Lighting

Functional and/or physical areas repository

1 AAA-D00Functional physical area: ........................................AAA-D00Short name: ..............................................................Mountain bicycleReferences: .............................................................. AAA-D00-0

2 AAA-D00-0Functional physical area: ........................................AAA-D00-0Short name: ..............................................................Mountain bicycle - GeneralReferences: .............................................................. AAA-D00-00

3 AAA-D00-00Functional physical area: ........................................AAA-D00-00Short name: ..............................................................Mountain bicycle - GeneralReferences: .............................................................. AAA-D00-00-00

4 AAA-D00-00-00Functional physical area: ........................................AAA-D00-00-00Short name: ..............................................................Mountain bicycle - General

5 AAA-D05Functional physical area: ........................................AAA-D05Short name: ..............................................................BicycleReferences: .............................................................. AAA-D05-0

AAA-D05-1AAA-D05-2AAA-D05-4

6 AAA-D05-0Functional physical area: ........................................AAA-D05-0Short name: ..............................................................Bicycle - GeneralReferences: .............................................................. AAA-D05-00


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S1000DLIGHTING-AAA-D00-00-00-00AA-0A1A-D


Applicable to:All

7 AAA-D05-00Functional physical area: ........................................AAA-D05-00Short name: ..............................................................Bicycle - GeneralReferences: .............................................................. AAA-D05-00-00

8 AAA-D05-00-00Functional physical area: ........................................AAA-D05-00-00Short name: ..............................................................Bicycle - General

9 AAA-D05-1Functional physical area: ........................................AAA-D05-1Short name: ..............................................................TBDReferences: .............................................................. AAA-D05-10

10 AAA-D05-10Functional physical area: ........................................AAA-D05-10Short name: ..............................................................TBD - GeneralReferences: .............................................................. AAA-D05-10-00

11 AAA-D05-10-00Functional physical area: ........................................AAA-D05-10-00Short name: ..............................................................TBD - General

12 AAA-D05-2Functional physical area: ........................................AAA-D05-2Short name: ..............................................................TBD1References: .............................................................. AAA-D05-20

13 AAA-D05-20Functional physical area: ........................................AAA-D05-20Short name: ..............................................................TBD1 - GeneralReferences: .............................................................. AAA-D05-20-00

14 AAA-D05-20-00Functional physical area: ........................................AAA-D05-20-00Short name: ..............................................................TBD1 - General


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15 AAA-D05-4Functional physical area: ........................................AAA-D05-4Short name: ..............................................................TBD2References: .............................................................. AAA-D05-40

16 AAA-D05-40Functional physical area: ........................................AAA-D05-40Short name: ..............................................................TBD2 - GeneralReferences: .............................................................. AAA-D05-40-00

17 AAA-D05-40-00Functional physical area: ........................................AAA-D05-40-00Short name: ..............................................................TBD2 - General

18 AAA-DA0Functional physical area: ........................................AAA-DA0Short name: ..............................................................WheelReferences: .............................................................. AAA-DA0-0

AAA-DA0-1AAA-DA0-2

19 AAA-DA0-0Functional physical area: ........................................AAA-DA0-0Short name: ..............................................................Wheel - GeneralReferences: .............................................................. AAA-DA0-00

20 AAA-DA0-00Functional physical area: ........................................AAA-DA0-00Short name: ..............................................................Wheel - GeneralReferences: .............................................................. AAA-DA0-00-00

21 AAA-DA0-00-00Functional physical area: ........................................AAA-DA0-00-00Short name: ..............................................................Wheel - General


MY CAVEAT



Applicable to:All

22 AAA-DA0-1Functional physical area: ........................................AAA-DA0-1Short name: ..............................................................Inner tubeReferences: .............................................................. AAA-DA0-10

23 AAA-DA0-10Functional physical area: ........................................AAA-DA0-10Short name: ..............................................................Inner tube - GeneralReferences: .............................................................. AAA-DA0-10-00

AAA-DA0-10-10AAA-DA0-10-20

24 AAA-DA0-10-00Functional physical area: ........................................AAA-DA0-10-00Short name: ..............................................................Inner tube - General

25 AAA-DA0-10-10Functional physical area: ........................................AAA-DA0-10-10Short name: ..............................................................Inner tube

26 AAA-DA0-10-20Functional physical area: ........................................AAA-DA0-10-20Short name: ..............................................................Tire

27 AAA-DA0-2Functional physical area: ........................................AAA-DA0-2Short name: ..............................................................Rear wheelReferences: .............................................................. AAA-DA0-20

28 AAA-DA0-20Functional physical area: ........................................AAA-DA0-20Short name: ..............................................................Rear wheel - GeneralReferences: .............................................................. AAA-DA0-20-00


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29 AAA-DA0-20-00Functional physical area: ........................................AAA-DA0-20-00Short name: ..............................................................Rear wheel - General

30 AAA-DA1Functional physical area: ........................................AAA-DA1Short name: ..............................................................Brake systemReferences: .............................................................. AAA-DA1-0

AAA-DA1-1

31 AAA-DA1-0Functional physical area: ........................................AAA-DA1-0Short name: ..............................................................Brake system - GeneralReferences: .............................................................. AAA-DA1-00

32 AAA-DA1-00Functional physical area: ........................................AAA-DA1-00Short name: ..............................................................Brake system - GeneralReferences: .............................................................. AAA-DA1-00-00

33 AAA-DA1-00-00Functional physical area: ........................................AAA-DA1-00-00Short name: ..............................................................Brake system - General

34 AAA-DA1-1Functional physical area: ........................................AAA-DA1-1Short name: ..............................................................Brake padsReferences: .............................................................. AAA-DA1-10

35 AAA-DA1-10Functional physical area: ........................................AAA-DA1-10Short name: ..............................................................Brake pads - GeneralReferences: .............................................................. AAA-DA1-10-00


MY CAVEAT



Applicable to:All

36 AAA-DA1-10-00Functional physical area: ........................................AAA-DA1-10-00Short name: ..............................................................Brake pads - General

37 AAA-DA2Functional physical area: ........................................AAA-DA2Short name: ..............................................................SteeringReferences: .............................................................. AAA-DA2-0

AAA-DA2-1AAA-DA2-2AAA-DA2-3

38 AAA-DA2-0Functional physical area: ........................................AAA-DA2-0Short name: ..............................................................Steering - GeneralReferences: .............................................................. AAA-DA2-00

39 AAA-DA2-00Functional physical area: ........................................AAA-DA2-00Short name: ..............................................................Steering - GeneralReferences: .............................................................. AAA-DA2-00-00

40 AAA-DA2-00-00Functional physical area: ........................................AAA-DA2-00-00Short name: ..............................................................Steering - General

41 AAA-DA2-1Functional physical area: ........................................AAA-DA2-1Short name: ..............................................................StemReferences: .............................................................. AAA-DA2-10

42 AAA-DA2-10Functional physical area: ........................................AAA-DA2-10Short name: ..............................................................Stem - GeneralReferences: .............................................................. AAA-DA2-10-00


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43 AAA-DA2-10-00Functional physical area: ........................................AAA-DA2-10-00Short name: ..............................................................Stem - General

44 AAA-DA2-2Functional physical area: ........................................AAA-DA2-2Short name: ..............................................................HandlebarReferences: .............................................................. AAA-DA2-20

45 AAA-DA2-20Functional physical area: ........................................AAA-DA2-20Short name: ..............................................................Handlebar - GeneralReferences: .............................................................. AAA-DA2-20-00

46 AAA-DA2-20-00Functional physical area: ........................................AAA-DA2-20-00Short name: ..............................................................Handlebar - General

47 AAA-DA2-3Functional physical area: ........................................AAA-DA2-3Short name: ..............................................................HeadsetReferences: .............................................................. AAA-DA2-30

48 AAA-DA2-30Functional physical area: ........................................AAA-DA2-30Short name: ..............................................................Headset - GeneralReferences: .............................................................. AAA-DA2-30-00

49 AAA-DA2-30-00Functional physical area: ........................................AAA-DA2-30-00Short name: ..............................................................Headset - General


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Applicable to:All

50 AAA-DA3Functional physical area: ........................................AAA-DA3Short name: ..............................................................FrameReferences: .............................................................. AAA-DA3-0

AAA-DA3-1

51 AAA-DA3-0Functional physical area: ........................................AAA-DA3-0Short name: ..............................................................Frame - GeneralReferences: .............................................................. AAA-DA3-00

52 AAA-DA3-00Functional physical area: ........................................AAA-DA3-00Short name: ..............................................................Frame - GeneralReferences: .............................................................. AAA-DA3-00-00

53 AAA-DA3-00-00Functional physical area: ........................................AAA-DA3-00-00Short name: ..............................................................Frame - General

54 AAA-DA3-1Functional physical area: ........................................AAA-DA3-1Short name: ..............................................................HornReferences: .............................................................. AAA-DA3-10

55 AAA-DA3-10Functional physical area: ........................................AAA-DA3-10Short name: ..............................................................Horn - GeneralReferences: .............................................................. AAA-DA3-10-00

56 AAA-DA3-10-00Functional physical area: ........................................AAA-DA3-10-00Short name: ..............................................................Horn - General


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57 AAA-DA4Functional physical area: ........................................AAA-DA4Short name: ..............................................................DrivetrainReferences: .............................................................. AAA-DA4-0

AAA-DA4-1

58 AAA-DA4-0Functional physical area: ........................................AAA-DA4-0Short name: ..............................................................Drivetrain - GeneralReferences: .............................................................. AAA-DA4-00

59 AAA-DA4-00Functional physical area: ........................................AAA-DA4-00Short name: ..............................................................Drivetrain - GeneralReferences: .............................................................. AAA-DA4-00-00

60 AAA-DA4-00-00Functional physical area: ........................................AAA-DA4-00-00Short name: ..............................................................Drivetrain - General

61 AAA-DA4-1Functional physical area: ........................................AAA-DA4-1Short name: ..............................................................ChainReferences: .............................................................. AAA-DA4-10

62 AAA-DA4-10Functional physical area: ........................................AAA-DA4-10Short name: ..............................................................Chain - GeneralReferences: .............................................................. AAA-DA4-10-00

63 AAA-DA4-10-00Functional physical area: ........................................AAA-DA4-10-00Short name: ..............................................................Chain - General


MY CAVEAT



Applicable to:All

64 AAA-DA5Functional physical area: ........................................AAA-DA5Short name: ..............................................................GearsReferences: .............................................................. AAA-DA5-0

AAA-DA5-1

65 AAA-DA5-0Functional physical area: ........................................AAA-DA5-0Short name: ..............................................................Gears - GeneralReferences: .............................................................. AAA-DA5-00

66 AAA-DA5-00Functional physical area: ........................................AAA-DA5-00Short name: ..............................................................Gears - GeneralReferences: .............................................................. AAA-DA5-00-00

67 AAA-DA5-00-00Functional physical area: ........................................AAA-DA5-00-00Short name: ..............................................................Gears - General

68 AAA-DA5-1Functional physical area: ........................................AAA-DA5-1Short name: ..............................................................MechsReferences: .............................................................. AAA-DA5-10

69 AAA-DA5-10Functional physical area: ........................................AAA-DA5-10Short name: ..............................................................Mechs - GeneralReferences: .............................................................. AAA-DA5-10-00

70 AAA-DA5-10-00Functional physical area: ........................................AAA-DA5-10-00Short name: ..............................................................Mechs - General


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71 AAA-DA5-2Functional physical area: ........................................AAA-DA5-2Short name: ..............................................................HubsReferences: .............................................................. AAA-DA5-20

72 AAA-DA5-20Functional physical area: ........................................AAA-DA5-20Short name: ..............................................................Hubs - GeneralReferences: .............................................................. AAA-DA5-20-00

73 AAA-DA5-20-00Functional physical area: ........................................AAA-DA5-20-00Short name: ..............................................................Hubs - General

74 AAA-DA5-3Functional physical area: ........................................AAA-DA5-3Short name: ..............................................................ShiftersReferences: .............................................................. AAA-DA5-30

75 AAA-DA5-30Functional physical area: ........................................AAA-DA5-30Short name: ..............................................................Shifters - GeneralReferences: .............................................................. AAA-DA5-30-00

76 AAA-DA5-30-00Functional physical area: ........................................AAA-DA5-30-00Short name: ..............................................................Shifters - General

End of data module


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S1000DLIGHTING-AAA-D00-00-00-00AA-0A2A-DApplicable to:All bicycles applicability


Lighting

Applicability common information repository

1 app-00000000AA022A-0000Applicability identifier: ............................................. app-00000000AA022A-0000Display text: ..............................................................Mountain bicycle and (Mountain storm Mk1 or

Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


MY CAVEAT



Applicable to:All bicycles applicability


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)


Brook trekker Mk9)

End of data module


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S1000DLIGHTING-AAA-D00-00-00-01AA-012A-AApplicable to:


Lights

Warning repository

1 warning-001Warning identifier: ....................................................warning-001


2 warning-002Warning identifier: ....................................................warning-002

WARNINGMake sure the light glass is not broken before handling it

End of data module


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S1000DLIGHTING-AAA-D00-00-00-02AA-012A-AApplicable to:


Lights

Caution repository

1 caution-001Caution identifier: .....................................................caution-001

CAUTIONDo not touch the glass of the bulb.

2 caution-002Caution identifier: .....................................................caution-002

CAUTIONMake sure that the glass is clean before installing it on the light.

End of data module


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Wiring data

Field description

Table of contents PageField description.......................................................................................................................................... 1References................................................................................................................................................... 1Wiring fields..................................................................................................................................................11 Wire data/fields descriptions......................................................................................................12 Harness data/fields descriptions............................................................................................... 23 Electrical equipment data/fields descriptions...........................................................................3

List of tablesTable 1 References....................................................................................................................................1Table 2 Wire data/fields descriptions......................................................................................................1Table 3 Harness data/fields descriptions............................................................................................... 2Table 4 Electrical equipment data/fields descriptions...........................................................................3

References


None

Table 1 References

Wiring fields

1 Wire data/fields descriptions

Field name Description

Wire number The wire number is the unique identifier for all electrical wires installed on thebicycle.

Wire type Wire type identifies the electrical wire in coded form, eg AP.

Wire gauge Wire gauge identifies the gauge of the wire in coded form, eg. 010.

Wire part number Wire part number gives the part number of the wire.

Harness ident Harness ident identifies the harness in which the wire is pre-assembled.

Wire sequentialnumber

Contains the sequential number of the wire, e.g. in the harness.

Table 2 Wire data/fields descriptions


MY CAVEAT






Wire informationcircuit code

Contains the identifier of the circuit to which the wire belongs.

Wire informationwire sectionidentification

Contains the identifier of the section to which the wire belongs.

Length Length identifies the length of the wire. The given value is approximately 10%higher than necessary to install the wire on the bicycle.

Color Color identifies the color of the wire sheating.

Twisting Twistig identifies wires, which are twisted together with a unique identifier.

Electric ident Electric ident shows the electrical identification, to which the wire isconnected. It is available for all electrical equipment, eg L1.

Contact Contact identifies the electrical contact to which the wire is connected.

Group code Identifies wires, which are connected to the same terminal lug.

Screens Screens identifies all screens that shield the wire. Wires shielded by the samescreen are identified by the same screens value.

Responsiblepartner company

The responsible partner company indicates the company responsible for theintegration of the wire to the bicycle.

Feed-through Identifies bunges through which the wire is routed.

Next higherassembly

Identifies the next higher assenbly, in which the wire is installed.

Table 2 Wire data/fields descriptions (Continued)

2 Harness data/fields descriptions


Harness ident Harness ident identifies pre-assembled wires, which are installed on thebicycle.

Harness Partnumber

Harness part number gives the part number of the harness identified by theharness ident.

Harness variant Harness variant identifies the variant of the harness in addition to the harnesspart number.

Harness issue Harness issue identifies the production variant of the harness in addition tothe harness part number.

Table 3 Harness data/fields descriptions


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Harnessnomenclature

Harness nomenclature identifies the harness by using a specific name.

Harnessseparation code

Harness separation code gives the separation code of the harness.

Minimumtemperature

Minimum temperature gives the minimum environment temperature in whichthe harness can be used.

Maximumtemperature

Maximum temperature gives the maximum environment temperature in whichthe harness can be used.

Harnessenvironment

Harness environment indicates that a harness is used in high vibriation or/andhydraulic areas.

Harness sleeve Gives the part number and/or the material of the sleeves used on the harness.


The responsible partner company indicates the company responsible for theintegration of the harness to the bicycle.

Table 3 Harness data/fields descriptions (Continued)

3 Electrical equipment data/fields descriptions


Electric ident Electric ident shows the electrical identification, which is available for allelectrical equipment, eg L1.

Part identification Part identification shows the part number of the equipment. In most cases thepart number is identical to the part desciption.

Location Location shows the installation position of the equipment on the bicycle.

Next higherassenmbly

Next higher assenmbly identifies the box or panel, in which the equipment isinstalled.

Position on nexthigher assenmbly

Gives the position on the next higher assenmbly, in which the equipment isinstalled.

Maximum numberof mountingpositions

Gives the maximum number of mounting positions on the next higherassembly.

Sibling plugidentification

Sibling plug identification contains the electric ident of the mating connector.

Transverse link Transverse link shows external or internal electrical connections of theequipment.

Table 4 Electrical equipment data/fields descriptions


MY CAVEAT







The responsible partner company indicates the company responsible for theintegration of the equipment to the bicycle.

Quantity Gives the quantity of multiple occurence equipment.

Table 4 Electrical equipment data/fields descriptions (Continued)

End of data module


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Wiring

Equipment lists

Ident CLC Qty Information Installation Applicability

L1PN: Front light

16 RPC:CAGE: U8025Name: UK MoD

• Locations:– Handle bars


L2PN: Rear light


• Locations:– Seat post


BattPN: Battery


• Locations:– FrameNHA: FIN ELO-Box


GenPN: Generator


• Locations:– Steering tube


RelPN: Relay




VV1PN: Distributionmodule

07 Transverse link:– Contacts:

– 1 +– 2 +– 3 +– 4 +

– Contacts:– 1 -– 2 -– 3 -– 4 -

RPC:CAGE: U8025Name: UK MoD



S1PN: Switch


• Locations:– Handle barsNHA: FIN ELO-Box


C_BattPN: Connector


• Locations:– FrameSibling plug id: FINC_BikeNHA: FIN ELO-Box



MY CAVEAT





Ident CLC Qty Information Installation Applicability

C_BikePN: Receptacle


• Locations:– FrameSibling plug id: FINC_BattNHA: FIN ELO-Box


DiodePN: Diode

18 2 RPC:CAGE: U8025Name: UK MoD

• Install. id: d1Locations:– FrameNHA: FIN ELO-BoxPos. on NHA:

Mount position: LH• Install. id: d2

Locations:– FrameNHA: FIN ELO-BoxPos. on NHA:

Mount position: RH


SensorPN: Speed sensor


• Locations:– Steering tube


T01PN: Tachometer


• Locations:– Handle bars


ELO-BoxPN: Electronic Box01

13 Max mount. pos.: 5RPC:

CAGE: U8025Name: UK MoD

• Locations:– Frame


FT1PN: GT-002-WD


• Locations:– FrameNHA: FIN ELO-BoxPos. on NHA:

Mount position: P1


FT2PN: GT-004-WD



Mount position: P2


FT3PN: GT-004-WD



Mount position: P3


(Continued)

End of data module


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Wiring

Wire list

ConnectionIdent

From To

Information Applicability

FL1AAState: Active

FIN: L1Contact: +Wire conn. code:

Electrical potential:Contact order: 1

NA code: 01

FIN: VV1Contact: 1 +

PN: P2201-PWire conn. code:

Electrical potential:TM grouping: 1Block grouping: 1Shunt grouping:1Contact order: 1

NA code: 03

Wire code:Wire type: APWire guages:– 010 (proj)

PN: W2201-KHarn. id: Lamp1Wire seq. no.: 1Circuit: 234Section: 567Twists:– Lamp1

Twisting type: 1Length: 1000Wire color: redU8025Routing:

Feed-throughs:FIN: FT3

Hole id: 1

Mountain bicycle and(Mountain storm Mk1or Brook trekker Mk9)

FL2AAState: Active

FIN: L1Contact: -Wire conn. code:


NA code: 01

FIN: VV1Contact: 1 -Wire conn. code:


NA code: 03


PN: 23-4567Harn. id: Lamp1Wire seq. no.: 2Twists:– Lamp1

Twisting type: 1Length: 1000Wire color: blueU8025Routing:


Hole id: 2


NC1VIState: Not active

FIN: VV1Contact: 4 +Wire conn. code:

Electrical potential:TM grouping: 1



MY CAVEAT





ConnectionIdent

From To


Block grouping: 1Shunt grouping:1Contact order: 4

NA code: 03RL1AAState: Active

FIN: L2Contact: +Wire conn. code:


NA code: 01




NA code: 03


Harn. id: Lamp2Wire seq. no.: 1Circuit: 134Section: 467Twists:– Lamp2

Twisting type: 1Length: 1500Wire color: redU8025Routing:


Hole id: 3


RL2AAState: Active

FIN: L2Contact: -Wire conn. code:


NA code: 01

FIN: VV1Contact: 2 -

PN: P2201-MWire conn. code:


NA code: 03


Harn. id: Lamp2Wire seq. no.: 2Twists:– Lamp2

Twisting type: 1Length: 1500Wire color: blueU8025Routing:


Hole id: 4


GE2AAState: Active

FIN: GenContact: GNDWire conn. code:


Potential conn.order: 1



Electrical potential:TM grouping: 1Block grouping: 1


Wire seq. no.: 2Length: 500U8025


(Continued)


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ConnectionIdent

From To


NA code: 01Group code: G1-

Shunt grouping:2Contact order: 7

NA code: 03

Routing:Feed-throughs:

FIN: FT2Hole id: 2

BT2AAContext: PN-AC-12561MFG: F0001Origin:Manufacturer

State: Active

FIN: BattContact: -

Install direct: AWire conn. code:


NA code: 01

FIN: C_BattContact: -

Install direct: BWire conn. code:


NA code: 02


Harn. id: Batt_01Context: PN-AC-12561MFG: F0001Origin:Manufacturer

Wire seq. no.: 2Twists:– Batt

Twisting type: 1Length: 400 [Critical]Wire color: blackU8025NHA: FIN ELO-Box


GE1AAState: Active

FIN: GenWire conn. code:



NA code: 01Group code: G1+

FIN: RelContact: 2

Function:Generator mode

Wire conn. code:Electrical potential:

Block grouping: 2Shunt grouping:2Contact order:102

NA code: 04


Wire seq. no.: 1Length: 500U8025Routing:


Hole id: 1


GE3AAState: Active





FIN: DiodeContact: AWire conn. code:

Electrical potential:Block grouping: 1Shunt grouping:1Contact order: 1

NA code: 04




Hole id: 3


(Continued)


MY CAVEAT





ConnectionIdent

From To


GE3ABState: Active





FIN: DiodeContact: AWire conn. code:


NA code: 04




Hole id: 4


BT1AAContext: PN-AC-12561MFG: F0001Origin:Manufacturer

State: Active

FIN: BattContact: +

Install direct: AWire conn. code:


NA code: 01

FIN: C_BattContact: +

Install direct: BWire conn. code:


NA code: 02


Harn. id: Batt_01Context: PN-AC-12561MFG: F0001Origin:Manufacturer

Wire seq. no.: 1Twists:– Batt

Twisting type: 1Length: 400 [Critical]Wire color: redU8025NHA: FIN ELO-Box


BA1AAState: Active

FIN: C_BikeContact: +Wire conn. code:


NA code: 02

FIN: S1Contact: BattWire conn. code:


NA code: 04




Hole id: 1NHA: FIN ELO-Box


(Continued)


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ConnectionIdent

From To


BA1ABState: Active

FIN: S1Contact: ONWire conn. code:

Electrical potential:Block grouping: 1Shunt grouping:1Contact order:102

NA code: 04

FIN: RelContact: 3

Function: Batterymode

Wire conn. code:Electrical potential:

Block grouping: 2Shunt grouping:1Contact order:103

NA code: 04




Hole id: 2NHA: FIN ELO-Box


BA2AAState: Active

FIN: C_BikeContact: -Wire conn. code:


NA code: 02




NA code: 03


Wire seq. no.: 2Length: 200U8025NHA: FIN ELO-Box


LL1AAState: Active

FIN: RelContact: 1Wire conn. code:


NA code: 04




NA code: 03


Wire seq. no.: 1Length: 500U8025NHA: FIN ELO-Box


GE4AAState: Active

FIN: GenContact: GNDWire conn. code:



NA code: 01Group code: G1-

FIN: RelWire conn. code:


NA code: 04




Hole id: 4


(Continued)


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ConnectionIdent

From To


GE5AAState: Logconn

FIN: DiodeContact: KWire conn. code:


NA code: 04




NA code: 04Group code: R1


GE5ABState: Logconn

FIN: DiodeContact: KWire conn. code:


NA code: 04




NA code: 04Group code: R1


T001State: Active

FIN: T01Contact: 1Wire conn. code:

Screen order: 2Electrical potential:

Contact order: 1NA code: 01Screens:– Type: 01, Lvl: 00,

Sty: 00

FIN: SensorContact: AWire conn. code:



Sty: 00

Wire code:Wire type: XYWire guages:– 010 (proj)

Harn. id: TachoWire seq. no.: 001Screens:– SCT1Twists:– Tacho

Twisting type: 1Length: 1200Wire color: yellowU8025


T002State: Active

FIN: T01Contact: 2Wire conn. code:



Sty: 00

FIN: SensorContact: BWire conn. code:



Sty: 00

Wire code:Wire type: XYWire guages:– 010 (proj)

Harn. id: TachoWire seq. no.: 002Screens:– SCT1Twists:– Tacho

Twisting type: 1


(Continued)


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ConnectionIdent

From To


Length: 1200Wire color: greenU8025

ND1State: Logconn

FIN: T01Wire conn. code:

Screen order: 1Spec. conn.:Electrical potential:


Sty: 01

FIN: T01Wire conn. code:


Contact order: 0NA code: 01Screens:– SCT1 Type: 03,

Lvl: 01, Sty: 01


ND2State: Logconn

FIN: SensorWire conn. code:

Screen order: 1Spec. conn.:Electrical potential:


Sty: 01

FIN: SensorWire conn. code:


Contact order: 0NA code: 01Screens:– SCT1 Type: 03,

Lvl: 01, Sty: 01


(Continued)

End of data module


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Wiring

Loom list

Ident Information Routing RPC Applicability

Batt_01Context: PN-AC-12561MFG: F0001Origin: Manufacturer

Battery_123Harn. var.: 123Harn. iss.: AHarn. name: BatteryharnessEMC: LS1Max temp.: 500 degFHigh vibr. env.: YesHydr. env.: YesSleeves:– PN: SPN1234

Material: Teflon

CAGE:U8025Name: UKMoD


Tacho Tachometer_101Harn. var.: 101Harn. iss.: AHarn. name: TachometerharnessEMC: LS2Min temp.: -10 degCMax temp.: 60 degCHigh vibr. env.: YesSleeves:– Material: Silicon



Lamp1 Front light_501Harn. var.: 501Harn. iss.: AHarn. name: Front lightharnessEMC: LS3Min temp.: -10 degCSleeves:– PN: SPN1234– PN: SPN4321



Lamp2 Rear light_503Harn. var.: 503Harn. iss.: AHarn. name: Rear lightharnessEMC: LS3Hydr. env.: Yes



End of data module